Offset Printing Technology

Prepress Basics

 2 Print Media Academy Media consultancy Print production

Printing is communication

Communication intention of the customer Media consultancy ideas sketches, rough drafts Ideas about the final product layout: binding proof Production planning Digital prepress

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Print production processes

Prepress

Press

Postpress

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Print production processes

Digital prepress Converting the communicative idea: Digital print pages are produced with the aid of a layout program on the computer Printing plate imaging A processor (RIP) converts digital pages for offset printing into extremely fine dots A laser writes these dots separately for each printing ink onto a printing plate

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Print production processes

Sheet-fed offset printing Printing: optimum transfer of visual information onto a printing material Data from prepress can control presettings and the ink coverage in the print High-end production makes extremely high demands on productivity and quality in the printing process Prerequisites: process preparation, color measuring technology and control technology

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Print production processes

Print finishing A finished product is produced from printed sheets folding gathering or collating the folded sheets stitching, binding cutting and ... The printed product is finished!

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General prepress workflow

Digital sheet assembly and imposition Creation of individual pages Proof: Positioning and color Color and text corrections Layout proof: Proof of the whole printing form Output: Computer to Workstation Layout External data transfer Record, create, process data: text, images, graphics Design pages Server (data management) film / plate Generating CIP4 data Data exchange Printing press Postpress

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Master copies for production

A print page may contain various elements:

Text

Image

Graphics

ABC
ew59
Computer, software, fonts Scanner, Digital camera Computer, software

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Master copies for production

Artwork masters: Lineart masters Only binary tone values can be printed in offset, i. e.: print or not print! Lineart masters consist only of such binary elements: smooth solid line or no line Single-color or multi-color lineart masters can be processed

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Master copies for production

Artwork masters: Continuous-tone images Images with a smooth progression in tone values: monochrome = tone values only in gray scales color = tone and color values Continuous-tone images must be converted technically, to obtain binary printing elements, i. e. continuous-tone images must be screened

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Master copies for production

Artwork masters: Continuoustone images Screening - to break down an image into individual binary printing elements Color separation - Color separation of a colored original produces partial images for printing with the process colors C, M, Y and additionally K

Monochrome and color continuous-tone images

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Master copies for production

Color separation

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Master copies for production

Data transfer It is becoming increasingly common for customers to transfer digital data for the production of a printed product External data are rarely print-ready, i. e. can be used for production without further processing Deficiencies may cause problems in keeping to deadlines interruptions in the production process higher costs
Data exchange: flyer title

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Master copies for production

Data transfer In order to avoid problems and therefore costs, intensive communication between customer and production is essential: So that we understand each other better! Check list for creating data In production Systematic control of data input = preflight check in the printshop Data management for data optimization

Digital reminder for data exchange (excerpt)

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Master copies for production

The image as information medium
Digital processes allow images to be produced synthetically It is rare to be able to recognize: true or false? Often the computer is used to create a "new" image from various other images and additional editing Composing = Manipulation? We are influenced more by an image than any text

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Master copies for production

... and this is how a new facade is produced lying with pixels? digital tools "make images

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Light and color

Our colorful world Color is an everyday sensory experience that we take for granted Color ... provides information is decorative affects us signalizes classifies shouts and ...

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Light and color

Our colorful world Color is an optical effect, i. e. a sensation conveyed by the eye and brain Nature itself is colorless. It only gets its color through light Color is light

Color in the system: CIELAB color solid

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Light and color

How do we see colors?
White light strikes an object Light rays are absorbed and reflected at the surface Reflected light rays reach the eye Color receptors in the human eye react to the received rays and pass them on to the brain cone-shaped receptors react to colored rays rod-shaped receptors react to black, white, gray

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Color receptors in the eye Colors of the spectrum

Light and color

White light Light source Prism

Model: A prism splits white light into the colors of the spectrum The visual perception of the beams takes place in the eye, the brain adds up all of the spectral energy to create a sensation: An image is formed from the information received gray or colored! White: The total of all colors of light is received Black: No light = no color visible

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Light and color

Additive mixing

Mixing colors of light Primary colors: red, green and blue Mixing these primary colors at full intensity produces white light. Increasing the addition of the colors of light leads to increasingly lighter mixed colors, if the intensity of the radiation is reduced, the lightness and color strength go down

Examples of technical equipment that "creates" colors by additive mixing are televisions, monitors, projectors, video devices

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Light and color

Subtractive mixing Certain color components of the light rays from white light striking a body are absorbed by the body, while others are reflected = Components of the light are subtracted Mixing body colors: Primary colors: cyan, magenta and yellow The optimum mixture of these primary colors produces black. Reducing the components equally produces gray values from dark to light

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Light and color

Subtractive mixing in the printing process
White paper reflects all of the light striking it The more ink is printed on the paper, the more light of certain radiation is absorbed The body's own color absorbs complementary radiation and reflects its own radiation, that is passed on by the eye to the brain: Color is a sensation
White light

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Light and color

Subtractive mixing in the printing process Image reproduction in four-color printing is achieved using the process colors cyan, yellow, magenta and black Tone and color values of multi-color images must be separated in the correct proportion into cyan, yellow, magenta and black components Screening: Each color separation must be converted into binary, printable elements Autotypical color mixing: To the observer there is both an additive as well as a subtractive response

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Scanning
Digitization of images: Scanning Scanners perform a computer-controlled digitization of single-color and multi-color images Three color separations are created by incremental scanning the original and concurrent color separation using RGB filters Software converts these RGB data into cyan, magenta and yellow, taking corrections into account The black color separation is produced either by using a special filter or by computation

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Screen technology
Screening of images
- Different tone values in the image are converted into extremely small binary print elements - Tone values can be represented by variablearea halftone dots: white paper completely reflects incident light rays, halftone dots of different sizes absorb more or less light! - The brain does not recognize individual dots through the eye, but rather a reflected brightness value

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Screen technology
Screen ruling For an autotypical (variable area) screen, the distance between the halftone dots from midpoint to midpoint is always the same The screen ruling gives the number of halftone dots in lines from midpoint to midpoint per unit length, e. g. l/cm lpi = lines per cm = lines per inch

The more halftone dots per unit, the finer the screen
1 cm

Screen ruling = number of lines per cm

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Screen technology
Screen ruling
The screen ruling (called screen frequency) specifies the fineness of the screen in the rendering of the picture information. The choice of screen ruling depends on the printing process and the surface of the printing material Rough paper surface = smaller screen ruling (< 54 l/cm) High quality and smoother paper surface = higher screen ruling (> 60 l/cm)
0.100 mm Halftone value = 50% Halftone value = 50%

40 l/cm screen K

80 l/cm screen K

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Screen technology
Screen angle Every autotypical, symmetrical screen has a regular structure, e. g. horizontal and vertical screen lines In four-color printing with autotypical screening, the individual colors must be angled, in order to avoid Moir Moir = formation of interference pattern Least noticeable angle = 450, standard practice for monochromatic halftone prints and for the key color in the image Standardized angle positions: 00, 150, 450 and 750, where Y is always at 00 Examples of Moir effects

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Screen technology
Screen output technology Laser systems in imagesetters output digital print pages to film or directly to a printing plate via a raster image processor (RIP) The smallest representable element of the imagesetting system, an imagesetter pixel, is called a dot The size of a dot is dependent on the resolution (fineness of reproduction) of the output system

Halftone value approx. 82%

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Screen technology
Screen output technology The resolution of an output system is given in dots per inch (dpi) For a screen ruling of 60 l/cm, a screen cell has an edge length of 1 cm : 60 = 0.01666 cm = 0.166 mm If an output system has a resolution of 2500 dpi, a screen ruling in the print of 60 l/cm (152 dpi) gives: Number of possible tone value levels = (2500 dpi : 152 dpi)2 = 256 256 = 16 x 16 imagesetter pixels

Rel

Dot

Rel = Recorder element Dot = Imagesetter pixel The laser beam requires for an area of 1 cm2 60 x 60 x 256 = 921,600 switching operations

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Screen technology
Classical dot shapes and dot contact
The four basic dot shapes.

2. Dot contact Cushionshaped Barrelshaped

Round

Square

60 line screen (60 l/cm) K K=0.166 mm 0.100 mm Halftone value = 40% d+0.010 mm -> 47% K

a) Square dot contact 1. Dot contact

d Halftone value = 40% d+0.010 mm -> 47.95%

b) Chains Dot contact (schematic)

Source: Ibm Training

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Screen technology
AM (amplitude modulated screen) FM (frequency modulated) screen

Source: Ibm Training

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Screen technology
In autotypical screening the halftone dots for the colors are arranged at specified angles. They form visible rosettes. Frequency-modulated screening uses neither set angles nor patterns of the same shape to distribute colors.

Source: Ibm Training

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Screen technology
What is FM or stochastic screening? Halftone dots are arranged randomly (frequency modulated) Dots are all the same size Their position varies Dot size is measured in microns ( meter or 1/1000mm) A 28 FM screen corresponds in gray values and definition to a conventional screen of about 300 lpi = 120 line screen

Source: Ibm Training

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Screen technology
Large number of finely distributed small halftone dots Distance or number of dots varies Dot size remains constant Advantages Avoids Moir and offset rosettes Increase in detail resolution Disadvantages Tighter specifications due to smaller dot size Greater dot gain
Much better reproduction of small type sizes particularly for script types.

Source: Ibm Training

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Creating documents
Creating digital documents Entering texts, graphics, pictures Integration of all elements of a print page according to the page layout Digital proofing Position proof Color proof Go-ahead by the customer

Type

Type

Type

 38 Print Media Academy Transfer of information to the printing form

Digital code Computers use a binary code, information is represented in the form of 0 and 1 = 1 bit (binary number) A group of 8 bits is one byte and so 256 definitions or switching states: 1 bit = 2 definitions: 0 or 1 2 bits = 4 definitions 8 bits = 256 definitions = 1 byte

ASCII code

Morse signals

A A B B 1 2

01000001 01100001 01000010 - 01100010 00110001 - - - 00110010 - - -

 39 Print Media Academy Transfer of information to the printing form

A bitmap A digital, checkerboard structure of all the information Recording, saving image data in scanners and digital cameras Control of imaging systems and printers for output The digital representation for the output consists of bit or byte data = individually controllable pixels or picture elements The degree of fineness or resolution is given as dots per inch (dpi)
0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 0 1 1 1 1 1 1 1 0 0 0 0 0 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1 1 0 0 0 1 1 1 1 1 1 0 0 0 1 1 0 0 0 1 1 1 1 0 0 0 0 0 1 1 0 0 0 1 1 1 1 1 1 0 0 0 1 1 0 0 0 0 0 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1

 40 Print Media Academy Transfer of information to the printing form

Vector format Lineart masters and type, in which all of the elements are defined by precisely mathematically defined geometric points, e. g. vertices of a character These individual vector data are connected for outputting. Only then do they produce the filled in character as a bitmap Advantage of vector data Exact representation is independent of size and resolution Smaller data volumes

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Imposition
Preparation for the output of digital pages When printing several pages: Imposition on one printing form Imposition: The arrangement of the pages on a print sheet, so that after printing, folding and processing, the pages are in consecutive sequence. Imposition takes account of the: number and format of the pages size of the print sheet production in the printing press as well as folding and binding

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Imposition
Preparation for the output of digital pages:

Trim

Head

2 Printing lay

Trim

15 14 Foot

Trim

Trim

Head

The arrangement of the pages is determined with the aid of a folding layout After printing and folding: trim on three sides!

Gutter

Gutter

11 10

Example of theinner printing form of a 16 page print sheet

Trim

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Output technologies
Output of digital pages Computer to film Product = film for copying processes Computer to plate Product = printing plates, imaged externally in an imagesetter Computer to press Product = printing plates, film imaged internally in the printing press

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Output technologies
Output of digital pages RasterImageProcessor (RIP): conversion of the digital data into a bitmap of binary elements, the imagesetter pixels (dots) Imaging: Transfer of this binary information, e. g. by laser, onto film or printing plate Basis: Page description language PostScript and a corresponding software, e. g. software RIP Prinect MetaDimension

Text

Text
Digital document

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Output technologies
Output of digital pages Possible functions of the RIP Conversion of all text, picture and graphics data into a bitmap Assignment of screens to images Color separations of color images Trapping OPI: Substituting low-resolution image data in high-resolution original image data (Note: In laser and inkjet printers the RIP is already installed)

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Data formats
What do the following stand for in the process?

PostScript, PDF, PPF, JDF, CIP ...?

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Data formats: PostScript

PostScript...
is a page description language by Adobe, which describes exactly all elements of a page (text, image, graphics) and their position in the layout of the print page is a programming language for describing print pages is a printer-independent language for controlling output systems Fonts or PostScript fonts, so-called Type 1 fonts, give an exact mathematical description of the outer contours of characters

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Data formats: PostScript

PostScript functions Application-specific changes e. g. distortion, image magnification, gradient adaptation Graphical elements (pictures, graphics) are converted into halftones: dot shape, screen ruling, screen angle. Here specific settings, e. g. calibration, print characteristic curves etc. are taken into account A separate bitmap is generated for each color
%!PS line width /zoll {72 mul} def /rechteck % Routine {newpath .6 .4 moveto -.6 .4 lineto -.6 -.4 lineto .6 -.4 lineto closepath } def gsave 5 zoll 3 zoll translate 1 16 div setlinewidth 116 % Schleife 1 bis 6 {gsave .5 mul zoll dup scale % multiplizieren rechteck stroke grestore } for % SchleifenEnde grestore showpage

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Data formats: PDF

Portable Document Format, PDF... is a page-oriented PostScript data format by Adobe, with which platform-independent data may be exchanged produces relatively small files by reducing superfluous commands and structures can be read on different computer platforms using the free Adobe Acrobat Reader

Prepress Document

PDF file

PDF view

Workflow

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Data formats: CIP3 data

Electronic sheet assembly RIP Production data for film/ platesetters Thumbnails Ink presetting PPF Register marks Print control bars Color reference values Cutting marks Folding marks Stitching marks

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Data formats: JDF data

JDF- Job Definition Format JDF is a manufacturer-independent interface language Enables communication between devices in the graphics industry Is supplemented by status information Connection to MIS systems (vertical market software) Specification by the CIP4 consortium Description by so-called "ICS Interoperability Conformance Specifications Based on the XML file structure

Management

Prepress

Press

Postpress

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Color management
Color management system Prerequisite so that all components in a workflow are optimally aligned in accordance with the specified color standards Applications

Digital proof Production-based simulation of the intended printing process Preview of the print result and binding basis for the go-ahead

Profiling

Calibration

Standardization

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Color management
Color rendering problems in individual process steps

Scanner

Monitor

Proofer

Press

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Color management
ICC profiles
Problem: Graphical representation of the color space of a device Color spaces have different shapes and dimensions, i. e. each device has its own defined color space Basis of color management: ICC profiles describe the color reproduction of an input or output device according to ICC guidelines

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Color management
Process

Standardization

Optimization Prepress

Optimization Printing process

Process control

ICC profiles

Proof and standardized print

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Color management

Basis: device-independent CIELAB color space

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Color management
International standards Commission Internationale dclairage (CIE) Specification of the Lab color space 1976 Device-independent Based on human color perception International Color Consortium (ICC) Specification of ICC profiles 1994 Computer-independent Manufacturer-independent
-b -b -a -a +b +b

+a +a

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Color management
Information transfer using ICC profiles ...

Scanner, D-Cam ICC calculation for monitor, print, proof

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Color management
Profiles for input and output devices

Scanner

Monitors

Proofer

Printing presses

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RIP Raster Image Processor

PDF pages: content

Raster Image Processor

CTP or film imagesetter

Printing plates Bitmaps

Control data Positioning data: control data

(ink Co zon ntrol es, data reg iste r, )

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RIP Raster Image Processor

Calculation of the data takes place in the RIP (Raster Image Processor) The RIP requires data: Content PDF or PostScript individual pages Control data Positioning data for the pages and control elements Exposure of the finished print sheets onto plates The recorder requires data: Content Bitmaps Control data Register punching Plate selection (Multi Cassette Loader)

 62 Print Media Academy Computer to plate/ Computer to film

Technical equipment

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Imagesetter systems
Design features

Capstan imagesetter (flat-bed) Flat-bed systems image via a polygon mirror on roll material, which is transported in synchronization with the rotation Internal drum imagesetters Image on material that is cut to size (sheets cut to size from the roll) External drum imagesetter Direct the laser beam line by line onto a rotating drum, on which the material to be exposed is fixed

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Capstan imagesetter
Capstan system
Synchronization of the optical system Polygon Adjusting the luminous intensity mirror between the center and the edges of the material due to different beam lengths Suitable for film and polyester plates Low production costs Laser source Material

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CTP imagesetter
Internal drum imagesetter
digital data

Fixed laser unit

rotating mirror optic

Prism exposes image line by image line

Mirror

Plate

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CTF imagesetter
Internal drum system
High production costs with internal drum, film cut to size, high repeat accuracy Identical beam length in all positions Simple optical system (prism) Only one laser beam for exposing, from roll to sheet, from roll to roll Connection to the online processor Integrated register punching system for films and polyester plates

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CTP imagesetter
External drum imagesetter
digital data

Exposure unit is guided along the drum

optic drum

plate

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CTP imagesetter
External drum imagesetter

Short beam path means higher power output Exposure is performed using more than one beam at the same time Up to 384 laser lines per revolution at the same time Short exposure times Variable optical system Thermal printing plates

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Printing plates
Advantages and notes
Very short production times High-quality printing plates Optimum register accuracy Shorter makeready times Less waste during makeready All elements must be in digital form A digital proofing system is compulsory

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Integrated production
Production control and monitoring
Invoicing Delivery Historical costing Feedback of data Production monitoring Production planning Process planning Material administration Job input Quotation Cost estimation Inquiry

Stitching Folding Cutting ImageControl

JDF

Speedmaster CP2000

PrepressInterface

CtP exposure RIP Proofing Imposition Proofing Color management Trapping Color conversion Preflight PDF production

JDF Job Definition Format

The JDF is a manufacturer-independent interface language Enables communication between devices in the graphics industry Is supplemented by status information Connection to MIS systems (vertical market software) Specification by the CIP4 consortium Described by so-called "ICS Interoperability Conformance Specifications Based on the XML file structure

 Offset Printing Technology

Prepress Basics