Print color management and print production optimization
Optimization of print production includes: equipment state optimization and production process optimization. Equipment state optimization refers to the operation of each device in the printing production and the various environmental and material factors that match the equipment, so that the equipment operates in a stable and optimal state, and the efficiency of the equipment is fully utilized. Optimization of the production process refers to the process of minimizing the reduction and automation of the printing production process. From the perspective of color control, it involves the prepress and printing process. Figure 2 shows the production color management process after optimization.
1. Device status optimization
Equipment state optimization is the coordination and unification of the printing environment, printed materials and various hardware devices, mainly including the optimization of the printing machine and the optimization of the prepress equipment. Prepress equipment is optimized for scanners, computers, monitors, laser imagesetters, CTP and digital proofers. The optimization method is to stabilize the printing process parameters through dataization and normalization, as follows:
1) Standardization and standardization of the printing environment
The printing environment mainly refers to the temperature and humidity of the pre-press and printing workshop, lighting conditions, etc. The standardization and standardization of the printing environment should be based on national or international printing industry standards. The temperature and relative humidity of the workshop should be kept in an optimal state to minimize static electricity, minimize dust and paper dust on film, plates and equipment, maintain paper stability, and minimize run-up. Problems with plates, plates, and inks. The standardization of lighting conditions requires the establishment of a standard observation environment, such as the neutral gray of the workshop wall, using D65 or D50 standard light source and light box to ensure the stability and consistency of image manuscript and printed sample observation.
2) Standardization of printed materials
The standardization of printed materials includes the standardization of material selection, material testing and performance data file creation, and it is best to implement relevant quality standards (such as the ISO9002 standard system). Printing companies should establish standards for material selection and purchase, and inspect and test raw materials, determine the performance of materials, the matching between materials and the compatibility of materials and equipment, and establish material data files to standardize printed materials. management. Printing materials mainly include: inks, plates, blankets, rollers, paper and fountain solution.
3) Calibration and normalization of the display
In the prepress environment, the requirements for the display are high, and the color rendering characteristics of the display are affected by various factors such as the lighting environment and the brightness of the display. The ideal lighting environment for the display requires the window to be covered with heavy dark curtains to avoid interference from external light sources and to prevent the influence of ambient light on the color perception of the human eye. In addition, the display itself needs to be calibrated before use. Although the display is factory-tested and calibrated at the factory, no two displays are identical, and the color reproduction performance of the display changes over time. The display can be calibrated with a screen calibrator. The calibration items mainly include brightness, contrast, gamma value, and fluorescing type.
4) Calibration and normalization of the scanner
Most scanners self-calibrate at startup, and scanners with auto-calibration perform a self-test with a built-in reference. For scanners that do not have an auto calibration function, they must be calibrated. Scanners can generally be calibrated using the IT8 color scale.
5) Standardization of the film output process
The normalization of the film output process is to ensure the quality of the film output. Optimization should begin with the press and then return to the prepress system and color separation. Press optimization requires standard setting of the various components of the press, knowing what problems may occur in the printing, evaluating the quality and compatibility of the printed materials, and finally determining the optimal working state of the press and stabilizing this state.
Including the selection of the film, the test of the performance of the film, the control of the temperature and concentration of the developer, and the establishment of the data file of the film output. There are two main factors in the quality of the film output: the film density and the linearization control of the film recording dots. The film density generally requires a minimum density value of not more than 0.07 and a highest density of not less than 3.5. The linearization function of the dot can be set in the RIP, in order to ensure that the dot can be correctly recorded on the film.
6) Standardization of traditional printing process
The standardization of the traditional printing process reflects the printing concept as the center of printing. The high-quality, high-efficiency standard printing plate has a great contribution to improving the overall printing production efficiency. The standardization of the printing process includes: keeping the printing shop clean and dust-free, the humidity meets the requirements, ensuring the stable performance of the printing machine, mastering the correct exposure and development time, and making good use of various testing tools.
7) Standardization of CTP plate making
CTP platemaking shortens the print production cycle and improves printing efficiency. Compared with the traditional plate making process, CTP has the advantages of high timeliness, good dot quality, and wide range of repeatable tone levels. The standardization of CTP platemaking should refer to the traditional printing process parameters to establish a good digital production environment.
8) Standardization of digital proofing
Digital proofing is the process of directly outputting printed proofs using digital originals. The main purpose is to achieve the customer's sample proof. Therefore, printing companies generally use customer satisfaction as a standard for proofing. But this non-professional subjective evaluation inevitably leads to many problems. For example, when the print does not achieve the color effect of the sample, there will be conflicts between the customer and the company. When the printed matter matches the proof, the quality of the next proof cannot be guaranteed because the company does not have a quantitative measure of the proof. In order to solve these problems, printing companies must develop standardized digital proofing documents to standardize digital proofing. The standardization of digital proofing includes selecting a suitable digital printer and supporting paper and ink, collecting data based on printing, realizing the color gamut of digital proofing machine, and regularly detecting and maintaining the digital proofing system.
9) Standardization of printing presses
The purpose of the press standardization is to find the best match between the press and the printed material, to determine the maximum ink density and dot gain characteristics of the press, which must be completed through a series of tests. The printing parts of the printing press shall be set according to the manufacturer's instructions, including the setting of the ink roller and the water roller, the compression setting of the printing blanket, the correctness of the printing plate and the blanket, and the printing machine. Cleaning and lubrication of paper devices, cleaning and lubrication of transfer systems and delivery devices. On this basis, the material and printing machine performance matching test is carried out to determine the optimal state of the printing machine and to digitize.
2. Production process optimization
It mainly includes two aspects: optimizing ink pre-setting and optimizing the control of the color reproduction process.
(1) Optimize ink presets
Ink presetting refers to the determination of the preset value of the printing press ink. There are three methods for ink pre-setting: manual experience setting, plate scanning setting, and ink preset data directly from the pre-press link. The accuracy and efficiency of human experience are mainly determined by the printing production personnel. It is difficult to digitize and standardize, and the formation of experience takes a long time. The plate scan setting refers to scanning and analyzing the graphic information in the yellow, magenta, cyan, and black plates by the plate scanner, obtaining the ink preset data, and setting the preset data through the storage device or the network. Passed to the press control center and ultimately reflected on the press. Its accuracy and efficiency depend on the accuracy of the plate scanner, the speed of scanning and the speed of data transfer. The third method is to directly generate ink preset data from the prepress link. The system for generating the ink preset data is a digital workflow. In the digital workflow, the preset data is transferred to the printer through a memory or network using a PPF (PrintProductionFormat) file. The control center is finally reflected on the press, as shown in Figure 3. Comparing the three methods, the third method is faster, more stable, easier to implement data and standardization, and can better optimize the printing production process.
(2) Optimize the control of the color reproduction process
The color reproduction process is controlled by real-time collection and analysis of printed images through some online print quality monitoring systems, and the results are fed back to the prepress link and the print console for timely correction. The optimization of the color reproduction process is mainly to establish an effective automatic color reproduction control system to bridge the communication between prepress and printing and improve the effective running time of the printing press.
Print color management and print production optimization
Optimization of print production includes: equipment state optimization and production process optimization. Equipment state optimization refers to the operation of each device in the printing production and the various environmental and material factors that match the equipment, so that the equipment operates in a stable and optimal state, and the efficiency of the equipment is fully utilized. Optimization of the production process refers to the process of minimizing the reduction and automation of the printing production process. From the perspective of color control, it involves the prepress and printing process. Figure 2 shows the production color management process after optimization.
1. Device status optimization
Equipment state optimization is the coordination and unification of the printing environment, printed materials and various hardware devices, mainly including the optimization of the printing machine and the optimization of the prepress equipment. Prepress equipment is optimized for scanners, computers, monitors, laser imagesetters, CTP and digital proofers. The optimization method is to stabilize the printing process parameters through dataization and normalization, as follows:
1) Standardization and standardization of the printing environment
The printing environment mainly refers to the temperature and humidity of the pre-press and printing workshop, lighting conditions, etc. The standardization and standardization of the printing environment should be based on national or international printing industry standards. The temperature and relative humidity of the workshop should be kept in an optimal state to minimize static electricity, minimize dust and paper dust on film, plates and equipment, maintain paper stability, and minimize run-up. Problems with plates, plates, and inks. The standardization of lighting conditions requires the establishment of a standard observation environment, such as the neutral gray of the workshop wall, using D65 or D50 standard light source and light box to ensure the stability and consistency of image manuscript and printed sample observation.
2) Standardization of printed materials
The standardization of printed materials includes the standardization of material selection, material testing and performance data file creation, and it is best to implement relevant quality standards (such as the ISO9002 standard system). Printing companies should establish standards for material selection and purchase, and inspect and test raw materials, determine the performance of materials, the matching between materials and the compatibility of materials and equipment, and establish material data files to standardize printed materials. management. Printing materials mainly include: inks, plates, blankets, rollers, paper and fountain solution.
3) Calibration and normalization of the display
In the prepress environment, the requirements for the display are high, and the color rendering characteristics of the display are affected by various factors such as the lighting environment and the brightness of the display. The ideal lighting environment for the display requires the window to be covered with heavy dark curtains to avoid interference from external light sources and to prevent the influence of ambient light on the color perception of the human eye. In addition, the display itself needs to be calibrated before use. Although the display is factory-tested and calibrated at the factory, no two displays are identical, and the color reproduction performance of the display changes over time. The display can be calibrated with a screen calibrator. The calibration items mainly include brightness, contrast, gamma value, and fluorescing type.
4) Calibration and normalization of the scanner
Most scanners self-calibrate at startup, and scanners with auto-calibration perform a self-test with a built-in reference. For scanners that do not have an auto calibration function, they must be calibrated. Scanners can generally be calibrated using the IT8 color scale.
5) Standardization of the film output process
The normalization of the film output process is to ensure the quality of the film output. Optimization should begin with the press and then return to the prepress system and color separation. Press optimization requires standard setting of the various components of the press, knowing what problems may occur in the printing, evaluating the quality and compatibility of the printed materials, and finally determining the optimal working state of the press and stabilizing this state.
Including the selection of the film, the test of the performance of the film, the control of the temperature and concentration of the developer, and the establishment of the data file of the film output. There are two main factors in the quality of the film output: the film density and the linearization control of the film recording dots. The film density generally requires a minimum density value of not more than 0.07 and a highest density of not less than 3.5. The linearization function of the dot can be set in the RIP, in order to ensure that the dot can be correctly recorded on the film.
6) Standardization of traditional printing process
The standardization of the traditional printing process reflects the printing concept as the center of printing. The high-quality, high-efficiency standard printing plate has a great contribution to improving the overall printing production efficiency. The standardization of the printing process includes: keeping the printing shop clean and dust-free, the humidity meets the requirements, ensuring the stable performance of the printing machine, mastering the correct exposure and development time, and making good use of various testing tools.
7) Standardization of CTP plate making
CTP platemaking shortens the print production cycle and improves printing efficiency. Compared with the traditional plate making process, CTP has the advantages of high timeliness, good dot quality, and wide range of repeatable tone levels. The standardization of CTP platemaking should refer to the traditional printing process parameters to establish a good digital production environment.
8) Standardization of digital proofing
Digital proofing is the process of directly outputting printed proofs using digital originals. The main purpose is to achieve the customer's sample proof. Therefore, printing companies generally use customer satisfaction as a standard for proofing. But this non-professional subjective evaluation inevitably leads to many problems. For example, when the print does not achieve the color effect of the sample, there will be conflicts between the customer and the company. When the printed matter matches the proof, the quality of the next proof cannot be guaranteed because the company does not have a quantitative measure of the proof. In order to solve these problems, printing companies must develop standardized digital proofing documents to standardize digital proofing. The standardization of digital proofing includes selecting a suitable digital printer and supporting paper and ink, collecting data based on printing, realizing the color gamut of digital proofing machine, and regularly detecting and maintaining the digital proofing system.
9) Standardization of printing presses
The purpose of the press standardization is to find the best match between the press and the printed material, to determine the maximum ink density and dot gain characteristics of the press, which must be completed through a series of tests. The printing parts of the printing press shall be set according to the manufacturer's instructions, including the setting of the ink roller and the water roller, the compression setting of the printing blanket, the correctness of the printing plate and the blanket, and the printing machine. Cleaning and lubrication of paper devices, cleaning and lubrication of transfer systems and delivery devices. On this basis, the material and printing machine performance matching test is carried out to determine the optimal state of the printing machine and to digitize.
2. Production process optimization
It mainly includes two aspects: optimizing ink pre-setting and optimizing the control of the color reproduction process.
(1) Optimize ink presets
Ink presetting refers to the determination of the preset value of the printing press ink. There are three methods for ink pre-setting: manual experience setting, plate scanning setting, and ink preset data directly from the pre-press link. The accuracy and efficiency of human experience are mainly determined by the printing production personnel. It is difficult to digitize and standardize, and the formation of experience takes a long time. The plate scan setting refers to scanning and analyzing the graphic information in the yellow, magenta, cyan, and black plates by the plate scanner, obtaining the ink preset data, and setting the preset data through the storage device or the network. Passed to the press control center and ultimately reflected on the press. Its accuracy and efficiency depend on the accuracy of the plate scanner, the speed of scanning and the speed of data transfer. The third method is to directly generate ink preset data from the prepress link. The system for generating the ink preset data is a digital workflow. In the digital workflow, the preset data is transferred to the printer through a memory or network using a PPF (PrintProductionFormat) file. The control center is finally reflected on the press, as shown in Figure 3. Comparing the three methods, the third method is faster, more stable, easier to implement data and standardization, and can better optimize the printing production process.
(2) Optimize the control of the color reproduction process
The color reproduction process is controlled by real-time collection and analysis of printed images through some online print quality monitoring systems, and the results are fed back to the prepress link and the print console for timely correction. The optimization of the color reproduction process is mainly to establish an effective automatic color reproduction control system to bridge the communication between prepress and printing and improve the effective running time of the printing press.
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