Workshop Design DevelopmentBudaörs

Technical Concepts

Flexography

One printing method withtwo different appearances.

Line Flexo Flexo Process

Pantone colours Process colours

Flexo line vs. Flexo process

► Duplex board► 6 spot colours from Pantone U

guide (2 overprinted)► Screen ruling: 24lines/cm (61

lpi)► Line printing of individual

colours► Approval: pdf file + Pantone

guide

► Claycoated board► CMYK + 2 spot colours from

Pantone C guide► Screen ruling: 48lines/cm (122

lpi)► Photographic images in a

predictable way► Approval: Epson proof

Flexo line Flexo process

Printing techniques

+ =

Flexo line

21

+ + + =

Flexo process

C M Y K

12

Spot Color Printing

CMYK

Process Color Printing

Flexography vs. offset

► Register moving: 0,1mm

► Screen ruling: 100lpc/133 lpi

► Nice highlights

Flexo Offset► Register moving: 0,2-0,3mm

► Screen ruling: 24-48lpc/61-122 lpi

► Highlights cannot be so light

Flexography vs. offset

Offset Flexo

Summary

Flexo line

Offset/Gravure

Flexo process

Qua

lity

ResolutionHigh resolution (54->)Spot color printing Medium resolution (48)

Flexo printing – the details

1. Text

2. Dot size

3. Line thickness/text size

4. Trapping/registration

5. Barcode

6. Colour/ink

7. Keyline

8. Artwork submission

9. Back panel

10. Co-production

1. Text

Texts in multiple colours will create misregister issues. Contour lines may be a solution.

Texts against a background colour may require a contour line to disguise misregister.

Positive Texts

In the exampleit’s possible to

visualize the resultsachieved in case ofregister variation.

For this reason we donot recommend theuse of positive texts,

lines or outlinesusing 2 or more colors.

Negative Texts

In the exampleit’s possible to

visualize the resultsachieved in case ofregister variation.

For this reason we donot recommend the

use of negative texts,lines or outlines over

2 or more colors.

Outlines

There are three different types of outlines we can apply.The outline is a resource used to avoid the “ghost” effect

in texts, when register variation occurs. See the examples below.

• Negative text and outline in 1 color

• Positive text in 1 color and white outlinewith transparence

• Positive text in 1 color and white outline

2. Dot size

Below 2 % (in file) you cannot reproduce dots on cliché. The minimum dots will become some 15% in printing.

100%

20%

5 cm

100%

20%

It is not possible to fade down to 0%

FL-min. percentage = 20% ±5

FP-min. percentage = 13% ±3

Dot gain

Minimum dot / Vignette

Offset/Gravure Flexo ProcessDesign

Hard EdgeMinimum dot

TP: 12%

Positive lines:min. 0.3 mm

Negative lines:min. 0.5 mm

Positive lines:min. 0.2 mm

Negative lines:min. 0.4 mm

Line thickness (one color) Line thickness (one color)

FLEXO LINE

FLEXO PROCESS

3. Line Thickness

Text Size

Positiveand negativetextwillgroworfill in dueto theratherhighprintcylinderimpression inflexographicprinting. Thisis mostnoticebleusing serif typefaces

4. Trapping / Registration

8 610400 021677OK

8 610400 021677NO

8 610400 021677OK

8 610400 021677NO

Print direction

80 - 200 %

Cro

ss d

irecti

on

m

in.

120 %

5. Barcode

6. Colour/ink

– Pantone matching system (PMS) is the most widely used custom colour system

– Tetra Pak use the Pantone Formula Guide as a standard reference– The PMS-guide consists of approximately 1000 specific ink colours– As there can be direct contact with food, colours should be

approved by FDA (some colours cannot be used, p.e. Rhodamine Red)

Flexo Printing – Grey Balance

► With grey balance we mean « white design elements » within a design such as cream, milk flow, vanilla cream etc.

► A grey shade in an image is created by the same amount of cyan-magenta-yellow. The grey shade in Flexo is therefore quite a dark one due to the min. printed dot of 13 % (13 % cyan + 13 % magenta + 13 % of yellow = 39 % ink coverage)

► In some cases to give the impression of grey only black is used

► But the grey balance can also be replaced by a Pantone colour

► Using a Pantone colour has the advantage of reproducing a clear, neat and fresh shade

► A single, light/clear colour leaves also the impression of a less hard break

7. Keyline (Template)

PLEASE DO NOT CHANGE TEMPLATE KEYLINE!!!

►The folder should contain:• Artwork in Illustrator format

• Images in Photoshop (eps)

• Pdf

8. Artwork submission

Necessary to define PANTONE colour to avoid problem...

...problem:different colour between screen PANTONE

and screen PROCESS color

M+Y PANTONE

Resolution of PSD file must be 300 dpi

Too many links: EPS, TIFF or PSD files

Too many masks and other effects on the layers!

Monitor vs. Print

RGB to CMYK conversion

In order to print what’s seen on the screen youhave to convert

RGB to CMYK.

Design considerations

A number of considerations has to be taken into account when creating a design

• Keyline

• EAN/UPC code

• Date stamp

• Opening

• Number of colours

• Logotypes

• Texts/lines

Design considerations

• Texts and lines should have a minimum size to be printable – see print specifications

•Avoid printing text and lines negative in more than one colour

• Avoid texts with serifs

•Contour lines

Design considerations

Opening

• There are a number of opening alternatives. Check with customer which one applies for the specific package.

Date stamp area• Position• Space• Position of text

Logotypes• Tetra Pak logotype on design ?• Recycling logos ?• Space On Pack - SOP? (check with customer)

Design considerations

Colour

•Co – print

•We cannot mix process colours with a special PMS colour as proofs will not reflect the true print result.

Avoid concentric

elements in different colors!

Avoid drop shadows in

different colours!

Misregister showing

white areas!The optimum is to put both the outline and the

drop shadow in the dark colour

Printing limitations

Art Work – Final check

Keyline

Font’s (or outlined text)

Barcode

Linked images

Image resolution

Printing technique

Number of inks

Pantone numbers

PDF or Jpeg preview

8. Back panel

►Pictures and letters have to fit on the back match

►Avoid small letters on the back match

9. Co-production

CONDITIONS:

-same quality, size & variantsame colors (max. 6)

ADVANTAGES:

-lower order quantity-lower set up charge per order

CHEAPER PACKAGINGMATERIAL

Co-production

56 CMYK

Pre-evaluation

►Tetra Pak is willing to support you with a pre-evaluation of the design from printing point of view before you send artwork for printing.

►Send us a Pdf of your draft and we are happy to comment on this.

Thank you!