Getting Maximum Results on Press

Printing presses form the core of the printing process. Every other area—as important as they are—play a support role to the presses. They’re simply the heart and soul of print communications.

Digitally driven, technologically advanced print platforms continue to expand the possibilities and accomplish amazing feats for marketers and publishers everyday. Modern printing presses handle just about any substrate, line screen, special inks or quantity you can throw at them. What’s more, they do it faster, more accurately and with more environmental responsibility than ever before.

Since quality reproduction is so important to the performance of your print materials, it pays to learn how to get the most out of whatever print process you’re using. Here are some tips to help you maximize your results on press.

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Match Your Line Screen to the PlatformDifferent print platforms require different line screens (the measure of how many halftone lines are printed in a linear inch) because of the way in which the equipment performs. To get the best results, it’s important to know the line screen range for each process as well as what is appropriate for different types of paper. Check with your supplier, but these are generally acceptable linescreen ranges: coldset/non-heatset web—100-133; heatset web—133-175; sheetfed—120-200. Linescreens don’t apply to digital printing. Presses will vary in the number of dots per inch (DPI) and levels of grayscale they can print. The crispness of the image reproduction depends upon the resolution of the image and the DPI of the press. You’ll get the best results by creating the images specifically for the printer’s dots per inch resolution.

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Match Pantone® Colors Properly in CMYK Some offset presses and most digital presses have 4-color capabilities only. That means you must specify Pantone® spot colors in their CMYK equivalents. To achieve the greatest possible accuracy, be certain to use the Pantone® Color Bridge™ guide. If you don’t have a book and you want your printer to provide the conversion, be sure to ask for a swatch since not every Pantone® color converts to CMYK with absolute accuracy.

Pay Attention to Maximum Ink/Toner DensitiesInk density is the thickness of the ink layer on the paper. The combination of all the process colors (Cyan, Yellow, Magenta, and Black) at full strength would be 400% coverage. Some platforms can print more density than others. Different papers can also handle more density than others. Again, you should always check with your supplier, but here are general guidelines: sheetfed—300%, 270% if UV coating; coldset/non-heatset web—260%/offset, 245%/groundwood, 235%/newsprint; heatset web—310%; digital—320%.

Choose Coldset Web Ink Colors CarefullySome colors can cause problems in the coldset web printing process. Pantone® colors with more than 50% yellow or transparent white in their formulas are a little like printing with Crisco®. When used as solids to tint stock or fill text boxes, the overprint ink will have a tendency to smear or set-off on the facing page because it can’t absorb properly. The rule of thumb is to select colors that have 50% or less transparent white in their formula for solid coverage.

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Gutter Jumps Can Land You In MudPresses and binders have more advanced controls than ever, but fluctuations do occur because of paper and other production factors. That makes gutter jumps (crossovers), and particularly running text between two facing pages, a bit risky. If you are going to require a complicated gutter jump, bring your printer into the conversation early so that you can do everything possible to minimize problems.

Know the Effect of Varnish on InkHigh gloss varnish deepens hues, creating a rich, even surface that reflects light. Meanwhile, dull varnish softens ink, moderating its intensity for a subtler effect.

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Think About Ink Applied Beyond the PressIf you’re creating direct mail response devices or any materials on which people will write, test your paper selection with ballpoint and felt-tip pens as well as pencil. Follow the same advice for laser or inkjet printing. Your provider can advise you, but there’s nothing like an actual test for ultimate reassurance.

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Know Your CoatingsCoatings are a popular design technique as well as a protectant. It’s good to know the basics so that you choose the right one. Varnish. A thin, oil- or solvent-based coating used in virtually all printing methods. Options include dull and gloss finishes, as well as tinting with opaque white or colored ink. Varnish can be applied overall or in very exacting spot applications. It can be wet trapped (in-line with other inks) or dry trapped (separate run after other inks have dried). Dry trapping will maximize contrast in instances where dull-gloss effects are desired. Varnish adds protection, but is the least protective of the coating options, though usually also the least expensive. It also has a tendency to yellow over time. Use varnishes on covers and jackets only when high durability and scuff resistance are not priorities. Aqueous Coating. A water-based coating used extensively in conjunction with sheetfed offset printing. Options include gloss and satin finishes, which can be applied overall or in spot applications. Aqueous coatings are generally wet trapped because they also serve as a quick drying, protective coating that allows sheetfed printers to print the reverse side of a press sheet almost immediately. Aqueous adds considerably more scuff protection than varnish, but not as much as UV or film lamination. Applications span a variety of uses in print—including book covers—and aqueous is the standard in packaging and POP applications because of its durability and cost-effectiveness. UV Coatings. A solventless coating cured instantly by UV radiation that is applied to a printed sheet for protection, appearance or specialty applications. UV is used extensively in screen printing, narrow web letterpress and flexographic printing. Options include gloss and dull finishes. It is very protective and scuff resistant but is generally more expensive in printed literature applications because UV is applied off-line in those instances.

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Film Lamination. A plastic film bonded by heat and pressure to a printed sheet or paperboard for protection or appearance. It is applied exclusively as an off-line process. Film lamination is extremely durable, scuff resistant and even waterproof, but comparatively slow and expensive. Applications are generally limited to book covers and other printed materials requiring the greatest durability.

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Avoid GhostsGhosting is a phenomenon that causes streaking or a faint reverse printed image to appear on a sheet where it was not intended. Typically this is a function of graphic design and tends to occur when there is a single image on a cover, for example, surrounded by a solid border. The border requires all the ink or toner any system can deliver, but the image “steals” ink and creates a noticeable variance. Sometimes the problem isn’t noticeable until drying. Printers look for ghosting-prone designs and have some tricks to minimize or eliminate it, but it’s best not to create the risk if at all possible.

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Use Ripon PrintersRipon Printers provides a wide range of services coupled with an industry-leading customer education program. Inquire about…

Premedia• Digital prepress

• Automated page production

• Collaborative workflow

• Soft proofing

Printing• Web heatset

• Web coldset

• Sheetfed

• Digital

Bindery• Folding

• Saddle stitching

• Perfect binding

• Layflat binding

• PUR binding

• Tipping

• Dot whacking

Mailing & Inkjet Imaging• Postal consultation

• CASS-certified list processing

• Inside, outside & thumbedge inkjet imaging

• Addressing & coding

• CoMail & CoPal

Fulfillment & Distribution• Internet-based

fulfillment

• Real-time reporting

• Cost-efficient shipping

Contact your Ripon Printers representative today, or send an email inquiry to sales@riponprinters.com.

Ripon Printers656 S. Douglas St.P.O. Box 6Ripon, WI 54971-0006

toll free 800-321-3136phone 920-748-3136fax 920-748-3741www.riponprinters.com