pre press
A V I S UA L J O U R N A L b y M I C H E L L E R A E N A
for the love of print pre-press and printing 2015
This book is made as a visual journal documenting the things I have learnt throughout the course. Pre-press and Printing is a course in Binus International University in which we learn printing techniques, finishing, and file preparation for printing. We go to various types of printing places and get visits from prominent people in the printing industry including Charlie SPS, Gusto, Pantone, and The Distillery Jakarta. This visual journal will cover these visits and more. The printing press is the greatest weapon in the armoury of the modern commander. -T. E. Lawrence
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contents. PLANNING YOUR PRINT 06
PRINTING SPECS
Things you need to cover 08
COLOR MANAGING
CMYK, RGB, and Spot Color 10
PA N T O N E
The universal color ID 12
FINAL ART
File preparation for printing
PRINTING 16
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SCREEN PRINTING
or Silk Screen Printing 18
OFFSET
The most common print 20
LETTERPRESS
The comeback vintage
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FINISHING 24
FINISHING OPTIONS
Die-cut, hot press, etc. 26
FA N C Y PA P E R
Paper stock choices 28
LASER CUTTING
Cutting-edge finishing
chapter one
Planning your print
CHAPTER ONE
PLANNING YOUR PRINT
printing specs When creating a design for print, planning is key. Preparing printing specifications (specs) may seem like a distraction from actual designing, but if you do it right, you’re likely to find that your printer is your best ally in making your design work and bringing the job in on budget. Here are things you need to keep in mind before printing.
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F I L E F O R M AT List the version of the operating system and software you will be using to create your files, particularly if you are working in a very old or very new program. The features of Mac OS® 9 and OS® X as well as versions of QuarkXPress®, Adobe® InDesign®, Illustrator® and Photoshop® must be taken into account by printers and service bureaus so they know how to open and work with your files. Make sure they can support your applications. FILE NAMING Unusual characters in a name have been known to cause a printer’s computer to crash. Keep file names under 30 characters and use letters and numbers only. Make sure your files are labeled with the correct extensions. Indicate which software version you used in preparing the file because some printers may not have the latest versions. Use Dash (-) or Underscore (_) instead of space. PROBLEMATIC SYMBOLS: / \ . : ; * # & INKS Specify the number and types of inks and varnishes you plan to use – e.g., four-color process, match colors, aqueous, metallics, fluorescents. Your printer may be able to show you how you can use more colors at little extra cost – e.g., add two match colors to a four-color job slated to run on a six-color press or use different inks on different forms. PA P E R S T O C K Include the basis weight, finish and grade name and color of the paper(s) you want to use in your specs. The paper’s basis weight and quality indicate how much ink the sheet can handle and its runnability on press. Basis weight also determines whether a book is thick enough to be perfect bound, needs scoring and can withstand special techniques such as embossing and diecuts.
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CHAPTER ONE
color
PLANNING YOUR PRINT
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RGB
CMYK
The RGB color system is used for digital media. Computer monitors emit color as RGB (red, green, blue) light. The RGB color model is an additive color model in which red, green, and blue light are added together in various ways to reproduce a broad array of colors. Before the electronic age, the RGB color model already had a solid theory behind it, based in human perception of colors.
The CMYK color system is used in printing inks for paper. Short for Cyan-Magenta-Yellow-Key, and pronounced as separate letters. CMYK is a color model in which all colors are described as a mixture of these four process colors. Because such printing uses inks of these four basic colors, it is often called fourcolorprinting. The “K” in CMYK stands for key because in four-color printing, cyan, magenta, and yellow printing plates are carefully keyed, or aligned, with the key of the black key plate.
SPOT COLOR
Special colors: any that are not CMYK process colors. The color gamut’s for spot color libraries, such as those associated with Pantone, usually extend beyond the ranges of the CMYK color gamutto reproduce a broad array of colors.
PLANNING YOUR PRINT
pantone matching system Pantone, Inc. is the authority on color, provider of color systems and leading technology for accurate communication of color. We got the chance to have a guest lecture by Graphic Designer and Pantone user, Leonard Pek.
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The Pantone Color Matching System is largely a standardized color reproduction system. By standardizing the colors, different manufacturers in different locations can all refer to the Pantone system to make sure colors match without direct contact with one another. One such use is standardizing colors in the CMYK process. The CMYK process is a method of printing color by using four inks— cyan, magenta, yellow, and black. A majority of the world’s printed material is produced using the CMYK process, and there is a special subset of Pantone colors that can be reproduced using CMYK. Those that are possible to simulate through the CMYK process are labeled as such within the company’s guides. However, most of the Pantone system’s 1,114 spot colors cannot be simulated with CMYK but with 13 base pigments (14 including black) mixed in specified amounts. The Pantone system also allows for many special colors to be produced, such as metallics and fluorescents. While most of the Pantone system colors are beyond the printed CMYK gamut, it was only in 2001 that Pantone began providing translations of their existing system with screen-based colors. Screen-based colors use the RGB color model—red, green, blue—system to create various colors.
Color of the year 2015 Marsala 18-1438
Pantone Color of the Year Annually Pantone declares a particular color “Color of the Year”. Twice a year the company hosts, in a European capital, a secret meeting of representatives from various nations’ color standards groups. After two days of presentations and debate, they choose a color for the following year; for example, the color for summer 2013 was chosen in London in the spring of 2012. The color purportedly connects with the zeitgeist; for example the press release declaring Honeysuckle the color of 2011 said “In times of stress, we need something to lift our spirits. Honeysuckle is a captivating, stimulating color that gets the adrenaline going – perfect to ward off the blues.” 11
CHAPTER ONE
PLANNING YOUR PRINT
final art prep When submitting your final artwork to the printer, there are some marks you need to put before printing to maintain maximum quality printing. These marks help with color handling, alignment and sizing.
PDF SUBMISSION CHECKLIST
Converted all colors to CMYK (including linked images) Removed any RGB or spot colors from your layout document (Adobe InDesign or Quark Xpress) Made sure linked image resolution is at least 300dpi at the desired output dimensions Performed any pre-flight checks to check for missing links or fonts Exported your file as a PDFx/1a file (as single pages and added a 3-5mm bleed and crop marks)
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When you produce a pdf file from your page layout or design program such as InDesign in the Adobe Creative Suite, you will see options on how to control the bleed area and marks on your final file. for printing, either digital or offset, if any graphic elements extend to the edge of the finished piece, you must design them to continue off the “page” and then include an extra border area to accommodate some trim. Since printers can’t print all the way to the edge of a finished sheet, the piece must be printed on larger paper and then trimmed down for a good finished product.
3 1 1 - CROP MARKS Crop marks are small lines offset from the edge of the finished piece that instruct where to cut or trim the final page to a finished size.
2 - BLEED MARKS Bleed is used so that there are no “whites” peeking on the pictures (if they go all the way to the edge). They look similar to crop marks.
3 - R E G I S T R AT I O N MARKS & COLOR BARS These sit outside the printed area and are used to correlate the different colors or plates used in offset lithography. Every type of printing uses a different, or many different, versions of the registration mark. This also helps with plate alignment.
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chapter two
Printing technique
CHAPTER TWO
PRINTING
screen printing Screen printing workshop with Charlie SPS, a screenprinting company based in Jakarta. They supply screenprinting products, tools, and services with an established clientelle (Nike, Puma, Quiksilver, etc.).
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Screen printing is a printing technique whereby a mesh is used to transfer ink onto a substrate, except in areas made impermeable to the ink by a blocking stencil. A blade or squeegee is moved across the screen to fill the open mesh apertures with ink, and a reverse stroke then causes the screen to touch the substrate momentarily along a line of contact. This causes the ink to wet the substrate and be pulled out of the mesh apertures as the screen springs back after the blade has passed. Basically, it is the process of using a mesh-based stencil to apply ink onto a substrate, whether it be T-shirts, posters, stickers, vinyl, wood, or other material. Screen printing is also a stencil method of print making in which a design is imposed on a screen of polyester or other fine mesh, with blank areas coated with an impermeable substance. Ink is forced into the mesh openings by the fill blade or squeegee and by wetting the substrate, transferred onto the printing surface during the squeegee stroke. As the screen rebounds away from the substrate the ink remains on the substrate. One color is printed at a time, so several screens can be used to produce a multicoloured image.
P RO CES S sc reen prin tin g
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CHAPTER TWO
PRINTING
offset printing As one of the most common forms of printing, we studied offset with Mr. Siswanto Sidharta and paid a visit to Gramedia Printing.
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Offset printing is a commonly used technique in which the inked image is transferred (or “offset”) from a plate to a rubber blanket, then to the printing surface. When used in combination with the lithographic process, which is based on the repulsion of oil and water, the offset technique employs a flat (planographic) image carrier on which the image to be printed obtains ink from ink rollers, while the non-printing area attracts a water-based film (called “fountain solution”), keeping the non-printing areas inkfree. The modern “web” process feeds a large reel of paper through a large press machine in several parts, typically for several metres, which then prints continuously as the paper is fed through. A few of its common applications include: newspapers, magazines, brochures, stationery, and books. Compared to other printing methods, offset printing is best suited for economically producing large volumes of high quality prints in a manner that requires little maintenance. Many modern offset presses use computer-to-plate systems as opposed to the older computer-tofilm work flows, which further increases their quality. In text reproduction, the type edges are sharp and have clear outlines. The paper surrounding the ink dots is usually unprinted. The halftone dots are always hexagonal though there are different screening methods
P RO CES S offset printing
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CHAPTER TWO
PRINTING
letterpress The vintage printing technique is making a big comeback to the design industry with increasing amounts of letterpress studios being started. The Distillery is the first in Jakarta.
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Letterpress printing is a technique of relief printing using a printing press, a process by which many copies are produced by repeated direct impression of an inked, raised surface against sheets or a continuous roll of paper. Letterpress is the oldest method of printing. Letterpress printing was the normal form of printing text from its invention by Johannes Gutenberg in the mid-15th century until the 19th century and remained in wide use for books and other uses until the second half of the 20th century. Letterpress uses thick 100% cotton paper, unlike offset or other forms of printing. The paper stock at the moment is all imported as Indonesia does not produce 100% cotton papers. The paper stock is also considerably thicker than most papers ranging from 300 gsm to 850 gsm. Because the papers are thick, the relief created by the press does not transfer to the back of the paper, unlike most debossing or embossing techniques. The depth of the relief is also customizable. Like the picture on the left side, there are varying depths of the reliefs to add dimension and difference in the artwork. The inks used for letterpress, unlike offset, are rubber-based. The process of letterpress is very labor-intensive and as such requires more time than other forms of printing. It is, however, making a comeback to the design world as it gives a very luxurious yet vintage feel.
The original letterpress machine: Heidelberg It’s these presses that you’ll see in many modern printing works. They are, however, no longer produced so parts are rare and expensive.
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chapter three
Finishing technique
CHAPTER THREE
FINISHING
finishing options Finishing is a general term printers use for anything that happens to a job after it’s been printed. We explore these.
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DIE-CUT Die-cutting is a process used in many different industries to cut a thin flat material (in our case, paper) into a specific shape using a steel cutting die. It can be used to punch out a decorative shape or pattern to incorporate within a larger piece, or it can be used to create the main shape of an object by cutting the entire sheet of paper in an distinct/designed way. A die-cut element draws attention to the 3D nature of paper and the character of the material itself. HOT FOIL hot foil stamping is the process of using heat and pressure to apply metallic foil or holograms to materials such as light papers, carton board, laminated board, plastics and corrugated board. The term hot foil stamping encompasses: Simple flat foil stamping. Hot foil gives luxurious effects to a design such as the one on the left where it is hot stamped in silver metallic foil. Hot foil stamping is also called poly in the Indonesian printing market. SPOT UV Spot UV is a high-gloss finish applied to a specific area of your print. It utilizes UV light to “cure� a varnish that is applied to paper or cardstock. This varnish can be applied to plain white cardstock, but is often applied to coat colorprinted paper products, sealing in their color, adding shine, and protecting the printed surface underneath. EMBOSS/DEBOSS Embossing and debossing are the processes of creating either raised or recessed relief images and designs in paper and other materials. An embossed pattern is raised against the background, while a debossed pattern is sunken into the surface of the material (but might protrude somewhat on the reverse, back side). Often used in combination with foil stamping, embossing/debossing alters the surface of paper stock or other substrates by providing a three-dimensional or raised/sunk effect on selected areas.
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FINISHING
paper stock
Paper stock has a wide variety of finishes, textures, and weights. Generally, it is divided into two: uncoated and coated paper.
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Uncoated stocks Generally more absorbent of ink than a coated paper, like its namesake, uncoated paper does not have a coating. It is generally not as smooth as coated paper and tends to be more porous. Uncoated paper is generally used for letterhead, envelopes and printed material that is aiming for a more prestigious or elegant look. College and University booklets, real estate brochures and menus for elegant restaurants are generally printed on uncoated paper to give them a prestigious feel. Ucoated paper, because of its high absorbancy, tend to display colors less vibrantly. Coated stocks Coated paper has a glossy or matte finish. Coated paper is generally very smooth and can be either very shiny (high gloss) or have a subtle shine (matte). Either way, coated paper will have a great effect on the appearance and usefulness of the printed item. Coated paper is more resistant to dirt, moisture and wear. It also makes the printed material more shiny. That is why it is generally used in the printing of magazines, book covers, glossy photos and art books. Coating restricts the amount of ink that is absorbed by the paper and how the ink bleeds into the paper. This is desirable for sharp and complex images as the ink stays on top of the paper and will not wick or bleed reducing the sharpness of the printed material. This same property can be unattractive for the back of business cards as the coated paper does not take well to pen ink or pencil and many people like to write on the back of business cards. The term paperweight, and number corresponding with each weight, refers to the thickness and sturdiness of the paper, not the actual weight of the sheet. This is why, sometimes, the same “weight� paper may be referred to as two different things. GSM is the universal measurement for paper weights and it is what is used in Indonesia. GSM stands for grams per square meter, which is the actual weight of the sheet.
PA P E R TE X TU R E S moh a wk st ra t h more
CHAPTER THREE
FINISHING
lasercut finishing Laser cutting is a type of subtractive manufacturing that cuts a design into a piece of material. We went to Gusto, Indonesia’s largest lasercut company.
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Laser cutting and laser fine cutting are applied for different kinds of materials where complex contours demand precise, fast and force-free processing. Lasers create narrow kerfs and thus achieve high-precision cuts. This method does not show any distortion and in many cases post-processing is not necessary as the component is subject to only little heat input and can mostly be cut dross-free. Almost all kinds of metals can be laser cut: mild steel, stainless steel and aluminum are the most common applications. Other laser cut parts are made from wood, plastics, glass and ceramics. Compared to alternative techniques like die cutting, laser cutting is cost-efficient already for small-batch production. The big benefit of laser cutting is the localized laser energy input providing small focal diameters, small kerf widths, high feed rate and minimal heat input. The beam is emitted from what’s called the ‘laser tube’ and is reflected by several mirrors up into the ‘laser head’ (like a periscope.) Within the head is a lens that finely focuses the beam onto the material surface for cutting or engraving. The kerf refers to how much of the material the laser takes away when cutting through. (the width of the groove made while cutting.) This varies from material to material and is also dependent on the laser beam tolerance i.e. the width of the beam.
This process involves three gases. These are carbon dioxide (CO2), nitrogen (N2), and oxygen (O). Shown is the process of laser cutting with a CO2 type machine.
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You can’t stop people printing what they want to print. - Alan Sugar
PRE-PRESS & PRINTING VISUAL JOURNAL 2015