Inxwell Manual

How to:

RUN WITH Mohawk’s exclusive papermaking process for Options & Navajo

INXWELL

INXWELL USERS MANUAL

: Introduction

Coated or

UNCOATED

?

FOR PAPER SPECIFIERS, IT SEEMS LIKE IT’S BEEN THIS WAY FOREVER.

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INXWELL USERS MANUAL

INXWELL USERS MANUAL

: Introduction

If you need great reproduction and runnability, you’ve got to print with a coated paper. OR, if you want great feel and character, you’ve got to run an uncoated.

What do you do?

: Introduction

when :

This “CHOICE” isn’t really your PREFERENCE? when :

Specification is forcing you to COMPROMISE DESIGN? when :

You’re tired of EITHER/OR paper?

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INXWELL USERS MANUAL

INXWELL USERS MANUAL

: Introduction

: Introduction

Discover that your needs and wants aren’t mutually exclusive. ***

INXWELL GIVES YOU THE LOOK AND FEEL OF AN UNCOATED — AND ALL THE PERFORMANCE YOU COULD ASK FOR.

RUN with INXWELL

WITH INXWELL YOU GET:

Crispness without the gloss, holdout without the hardness. > To bask in the glow

of color that doesn’t dull when it dries back. > Up to color densities faster, wasting

less time and paper in make-ready. > To put high-fidelity printing within the reach

of any printer. > To offer clients a 100% recycled paper made with windpower. > Multiple shades of white. > Several finishes.

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INXWELL USERS MANUAL

: Introduction

This handbook was created to provide designers, printers, print buyers and clients with the information they need to understand, specify and print on Mohawk Fine Papers’ proprietary, patented Inxwell papers.*

Contents ***

SEC.

01 ORIENTATION P. 8

It’s organized in four sections: SEC.

02 DEFINITION P. 10

SEC.

03 DEMONSTRATION P. 14

SEC.

04 SUGGESTIONS P. 28

* Options & Navajo

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INXWELL USERS MANUAL

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: Orientation

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: Orientation

People who know Mohawk Fine Papers know what we’re all about — uncoated papers with an unsurpassed reputation for their substance. Their soul. And for their performance.

But they might not know the story behind our most advanced paper. In fact, it’s been a closely held secret. Until now. The story begins in the early 1990s, when our tech-

nologists were presented with a formidable challenge: Can uncoated paper perform

more like a coated paper? Can we change the way paper and ink interact? And can we

Ink

improve printing as a result? These questions were answered in 1995 with the introduction of our patented Inxwell technology. Since then, Inxwell papers have been

embraced by thousands of discriminating designers, clients, print buyers and printers.

From web printed annual reports for industry leaders like IBM, Microsoft and BP

to advertising inserts for Banana Republic and recruitment brochures for Crate and Barrel, designers choose Inxwell papers for their most critical print projects.

Inxwell papers are exclusive to Mohawk, and include Mohawk Options and Navajo.

These papers were first developed and refined over the years in our quest to create

SWELL

the best uncoated printing papers in the world. Today, Inxwell papers continue to be

achievable only by Mohawk. They are distinguished by their extraordinary ink holdout, increased opacity and a smooth, easy-to-print surface. And they deliver to the uncom-

promising standards we set for ourselves, with vibrant color and minimal showthrough.

The nature of uncoated Inxwell papers makes them equal parts “high-tech” and “hightouch.” Both Navajo and Options combine extraordinary print fidelity with the “hand” that distinguishes a fine, premium text and cover grade. As a result, design firms can make an especially compelling case when shifting clients — and their perceptions —

? page 8

from coated to uncoated paper.

ALL OF THE DOT AND NONE OF THE DOUBT.

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INXWELL USERS MANUAL

SEC .

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: Definition

SEC .

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: Definition

So what is Inxwell? Simply put, it’s a patented process. Mohawk holds four U.S. patents on Inxwell, which together broadly cover two areas: the Inxwell formulation and its accompanying manufacturing technology.

2.1

THE FORMULATION

The Inxwell formulation is comprised of a few materials commonly used in the paper

The

making process, along with other, more unique, ingredients. In combination, these

ingredients provide a surface treatment with novel flow properties while in the wet state and exceptional print and optical properties when applied to paper.

2.2

THE TECHNOLOGY

The patents Mohawk has been granted for the Inxwell manufacturing technology

describe how the Inxwell formula is uniformly applied during the papermaking process, in small quantities, to improve ink holdout, enhance opacity, reduce showthrough and minimize print mottle.

SECRET IS

All printing papers — coated or uncoated — are surface-treated to prevent ink from

excessively soaking into the sheet during printing. Uncoated papers are traditionally treated with starch, but most of this sizing is absorbed into the sheet, leaving very little on the surface to do the job of providing ink holdout. The natural feel of the

paper comes through, but usually at a cost to print quality — especially to the detriment of four-color process imagery. Coated paper manufacturers counteract this effect by

adding significant amounts of mineral coating to the surface (as much as 10 pounds

per side). Coating creates a cold, hard surface that improves ink holdout — but when

(hold)out

up to 25% of the paper’s weight is devoted to coating, the result can be paper with less fiber and a limp, insubstantial feel.

THE MOHAWK FORMULA FOR AMAZING HOLDOUT AND PRECISE REPRODUCTION.

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INXWELL USERS MANUAL

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INXWELL USERS MANUAL

: Definition

SEC .

Mohawk’s Inxwell papers, Navajo and Options, represent an important breakthrough in these traditional processes. Unlike sizing, the Inxwell formulation sits up on the

surface of the paper, which means only a very small quantity is needed to provide ink holdout. This allows Navajo and Options to retain the natural feel and “hand” of

premium uncoated papers, while achieving high ink holdout for crisp dot definition.

The complete definition, then, of Inxwell is that it’s a surface treatment applied to Mohawk premium uncoated paper, in very small quantities, through a unique,

proprietary process. Inxwell is exclusive to Mohawk, as is the knowledge that created it. In fact, the defining attribute of Inxwell is the expertise and craftsmanship that Mohawk people bring to papermaking.

2

: Definition

MOHAWK’S INXWELL PAPERS: MOHAWK NAVAJO AND MOHAWK OPTIONS Mohawk Navajo is a virtuoso performer on any press. Navajo is the brightest,

smoothest uncoated paper available anywhere. Navajo is optimized for both digital

and offset presses, delivering brilliant color, high opacity, and superior print quality for all the ways you print. Acid free. 20% recycled. > Inxwell paper: superior ink holdout and opacity A cross-section of the surface of an uncoated sheet FIG. 2.1

> A Mohawk Digital Paper > Watermark-free writing

> Available in international A sizes Expressive Mohawk Options has the look & feel of traditional uncoated papers, but reproduces four-color photography with precision. Options features unusually high A cross-section of the surface of an uncoated Inxwell sheet FIG. 2.2

ink holdout and exceptional opacity. The line includes eight distinctive white shades and smooth and vellum finishes. Acid free. 30% and 100% recycled.

> Inxwell paper: superior ink holdout and opacity > A Mohawk Digital Paper > Green Seal certified

> 100% recycled is FSC- certified

> 30% & 100% recycled are process chlorine free and made with windpower A cross-section of the surface of a coated sheet FIG. 2.3

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INXWELL USERS MANUAL

SEC .

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: Demonstration

SEC .

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: Demonstration

Navajo and Options are Inxwell papers. ***

Inks WELL

THEY PRINT BETTER THAN ANY OTHER UNCOATED PAPER IN THE WORLD. Here’s why: 1. High ink holdout

8. Easy to print

2. High definition

9. Easy running

3. High density

10. Quick to dry

4. High contrast

11. Use less ink

5. High opacity /

12. Environmental sustainability

Low showthrough

!

13. The client / paper dilemma

6. Cross-platform

14. Economy

7. Smoothness

15. Conventional offset vs. UV

NOT A COATING. NOT A FINISH. JUST A GROUNDBREAKING PROCESS FOR FINE PRINTING.

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INXWELL USERS MANUAL

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3.1

INXWELL USERS MANUAL

: Demonstration

HIGH INK HOLDOUT

Ink holdout refers to the ability to keep the ink on the surface of the paper. It is an important factor in determining the potential print quality of a paper.

Inxwell papers have high ink holdout and keep more of the ink film on the paper

SEC .

3.3

3

: Demonstration

HIGH DENSITY

Print density is the measure of the amount of ink on the surface of the printed press

sheet. Because printing ink sits up on the surface of Inxwell papers, wet ink densities tend to be higher than traditional uncoated papers (for the same ink volumes). This means that Inxwell papers come up to color quickly and require up to 20% less ink than traditional uncoateds.

surface where you can see it. Not only do colors print brighter than on other uncoated papers, colors stay brighter. Process printing on traditional uncoated papers yields “dry back” averaging 10 – 15 points within a few hours of printing. Although printers have developed ways to compensate for dry back, the final image on traditional uncoated papers is typically softer and duller than when it first comes off press.

Please note: dry back is not related to drying time. Inxwell papers dry at about the same

3.4

HIGH CONTRAST

Higher ink holdout means that the ink you’re putting on the surface is working

harder for you. Shadows and midtones can print darker without getting muddy, which provides greater contrast and a richer-looking printed image.

rate as other smooth uncoated papers.

3.2

HIGH DEFINITION

The dot is the individual element that makes up a halftone or a photograph.

Dots print precisely on Mohawk Inxwell papers, with lower gain. Printing dots retain their integrity in all types of reproduction, especially in critical midtones

and three-quarter areas, which can appear muddy on traditional uncoated papers.

Knock out typography, even with fine serif type, holds its own on Inxwell papers.

FIG. 3.1 High ink holdout means that ink pigments have

less potential to penetrate a paper surface and cause dot gain. The result is greater definition of images, ink densities and contrast.

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INXWELL USERS MANUAL

SEC .

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3.5

INXWELL USERS MANUAL

SEC .

: Demonstration

HIGH OPACITY/ LOW SHOWTHROUGH

Opacity measures the percentage of light that can penetrate unprinted paper. The opacity of Inxwell papers is up to two points higher than other premium uncoated papers of comparable brightness, basis weight and smoothness.

In addition, Inxwell papers have less showthrough on printed material than other uncoated papers due to the better holdout. Overall, increased opacity of Inxwell

3.6

3

: Demonstration

CROSS PLATFORM

Inxwell papers are “cross-platform” papers. Early on, Mohawk recognized the potential of digital printing and became the first mill to adapt its papers “for all the ways you

print.” Inxwell papers meet customer needs for papers that print anywhere, any time, on any type of equipment, including digital printers, color copiers, offset presses,

and heatset web presses. There are Inxwell papers designed to perform across these various reproduction platforms and are optimized to meet the needs of the latestgeneration color printing and production equipment.

papers allows you to use brighter, smoother papers with less concern about

showthrough — giving you the opportunity to use lower basis weight papers and save money on paper or postage costs.

3.7

SMOOTHNESS

Smoother papers with uniform formation can provide crisper printed imagery. The

Inxwell process, when combined with Mohawk’s superior formation, creates a flatter, more uniform print surface. This allows Inxwell papers to print smoothly, with minimal print mottle.

All uncoated papers have hills and valleys, which occur naturally during the paper-

making process. Smooth papers are achieved by running the paper web between heated drums called a calender stack. After calendering, the hills and valleys in traditional

uncoated papers create microscopically different print surfaces, which can result in a galvanized look or lead to print mottle in poorly formed papers. As surface smooth-

ness increases on traditional uncoated papers, the likelihood of galvanizing or print

mottle also increases. Mohawk’s superior formation minimizes the difference between the hills and valleys, and Inxwell technology allows you to print smooth and supersmooth paper fearlessly.

FIG. 3.5 Inxwell papers give you high opacity without sacrificing brightness — a common trade-off with conventional papers.

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INXWELL USERS MANUAL

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3.8

INXWELL USERS MANUAL

SEC .

: Demonstration

EASY TO PRINT

Inxwell papers have high ink holdout and keep more of the ink film on the paper surface where you can see it. Not only do colors print brighter than on other uncoated papers, colors stay brighter.

Process printing on traditional uncoated papers yields “dry back” averaging 10 – 15 points within a few hours of printing. Although printers have developed ways to

3.10

3

: Demonstration

QUICK TO DRY

To maintain profitability, printers need to keep jobs moving through the pressroom.

And in our just-in-time world, clients often have excruciatingly tight print deadlines.

That’s why it’s important to turn jobs quickly — and why drying time has become

an important measure of a paper’s efficiency. Drying time refers to the amount of time needed for an ink to become rub-free or tack-free, so a sheet can return to the press

for a second pass or move on to the bindery. When it comes to drying, you can expect Inxwell papers to be just as fast as other smooth uncoated papers.

compensate for dry back, the final image on traditional uncoated papers is typically softer and duller than when it first comes off press.

3.11

USE LESS INK

Inxwell papers love ink. But because ink sits on top of the paper, they don’t need a 3.9

EASY RUNNING

The runnability of a paper has to do with a paper’s physical performance through the press. How well can the paper withstand the rigors of the press? How well does

lot of it. Printers tell us that they use, on average, 20% less ink when they print

on Inxwell papers. This contributes to printer profitability and saves money for the client, of course, but it’s also less impactful on the environment.

the paper resist stress? Does the paper give? What is the paper’s stretch resistance?

Dimensional stability? Our Inxwell papers are easy-running and are exceptionally stable on press, making every printer more efficient.

FIG. 3.11 In printers’ real-world experiences,

the excellent holdout and on-press efficiency of Inxwell papers have reduced their ink usage by 20%.

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INXWELL USERS MANUAL

SEC .

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3.12

INXWELL USERS MANUAL

: Demonstration

SEC .

ENVIRONMENTAL SUSTAINABILITY

Beyond providing the highest quality papers in the market, Mohawk has a strong commitment to environmental excellence.

In 2003, we became the first paper mill — and the only manufacturing facility in

New York — to use windpower in our operations. Mohawk offers two Inxwell grades manufactured with wind energy: FSC-certified Mohawk Options 100% PCW and

Mohawk Options 30% PCW. Both grades are also process chlorine free and certified

3.13

3

: Demonstration

CLIENT PAPER DILEMMA

Some clients demand coated paper — end of discussion. But many designers prefer the tactile and substantial feel that premium uncoated papers bring to a project.

From experience, designers and printers have learned that our Inxwell papers are

an effective way to transition clients to an uncoated paper. Inxwell papers can often meet client expectations for vibrant color and sharp detail while providing the bulk, brightness, and tactility that only premium uncoated papers can provide.

by Green Seal.

3.14

ECONOMY

Inxwell papers offer more value per production dollar. In addition to the ink conserva-

tion and runnability mentioned on previous pages, the opacity advantages of Inxwell papers over comparable premium uncoated papers means that Inxwell papers can

be specified in lower basis weights (which saves money). This is especially helpful for direct mail or for other projects where paper weight is a concern. And with proper

pre-press, Mohawk’s Inxwell papers allow printers to achieve UV-like printed results on conventional presses, enabling designers to avoid the premium typically charged for UV printing.

FIG. 3.12 We recognize end-users’ natural interest in producing print materials with the least environmental impact possible. Mohawk’s ongoing environmental risk reduction programs offer your clients an unmatched degree of assurance.

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INXWELL USERS MANUAL

MOHAWK NAVAJO BRILLIANT WHITE SMOOTH 80 T

4C + RED TOUCH (UV)

SEC .

3

3.15

: Demonstration

CONVENTIONAL OFFSET VS. UV

UV printing refers to the method of drying inks with ultraviolet radiation. UV printing can be achieved with special UV presses or presses that have been retrofitted to run co-cure inks.

Although only available in a small number of print shops, and often more expensive

than conventional offset, this technique has been embraced by many uncoated paper mills in their paper promotions because it produces intense color on uncoated paper.

With proper pre-press, Mohawk’s Inxwell process allows conventional printers to

achieve uncoated image results that rival UV. Mohawk Inxwell papers print with UVlike results because of their high ink holdout, which minimizes dot gain and holds

dot shape. As a result, Mohawk Options and Navajo give all printers in all markets the ability to produce high-end designer-quality printing on uncoated papers.

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MOHAWK NAVAJO BRILLIANT WHITE SMOOTH 80 T

4C

+

SPOT DULL VARNISH

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INXWELL USERS MANUAL

SEC .

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SEC .

: Suggestions

4

: Suggestions

While they are technologically advanced, Inxwell papers don’t require you to have a Ph.D. to print on them. In fact, Inxwell papers perform well in all of the popular printing processes: offset, heatset web, waterless and digital. Inxwell papers should be treated the same way as all uncoated papers — but with a few important differences.

Refining your

4.1

PRE-PRESS CONSIDERATIONS

Film preparation ***

Inxwell papers are noted for their ability to render unusually refined photographic

reproduction. Because the papers produce such high ink densities, detailed midtones, smooth shadows and silhouettes are easy to achieve. To achieve the best results, printers should adjust their curves in pre-press.

Some printers have found that the common ink saturation techniques used for

uncoated papers such as UCR (undercolor removal) or GCR (gray component replacement) help to avoid oversaturation of dark shadow areas and heighten image con-

trast. Similarly, some printers have used a skeletal black touchplate in the shadow areas (after UCR) to approximate the clarity, density and contrast of UV printing.

While these refinements may help the conventional printer achieve high-fidelity

results they are not necessary for an acceptable print job. Most printers prefer a

IMAGE

screen ruling of 200 lines per inch, although we have seen excellent results using screens from 150 to 300, as well as stochastic.

HELPFUL HINTS FOR GETTING THE MOST FROM INXWELL.

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INXWELL USERS MANUAL

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4.2

INXWELL USERS MANUAL

: Suggestions

CONSIDERATIONS ON PRESS

SEC .

4

: Suggestions

Digital printing/production on Inxwell papers ***

Sheetfed lithography ***

Ink types No special inks are required to run Inxwell papers.

TAC Like other uncoated papers, a total area coverage of 260% is a good target.

Also known as tone value sum (TVS) and total ink limit (in Photoshop).

The quality and reliability of digital printing continues to improve as the per-page costs decline. Mohawk’s Inxwell papers are optimized for all the leading digital

presses, including color copiers, Xeikon-engined presses, and direct imaging presses.

In addition, Inxwell papers provide acceptable results in inkjet printers. They are

engineered to anticipate technology shifts in digital and to extract the best performance from the latest, next-generation digital “printers.”

Ink densities Since Mohawk Inxwell papers require less ink and water than other uncoated papers, for clean and sharp print, nominal wet ink densities should approximate: K-1.30, C -1.15, M-1.15, Y- 0.85.

4.3

Water levels As always, minimize water levels and run with a conductivity below

Drying

1,500 micromhos and a pH level between 4.5 to 5.5 for optimal water performance.

Match colors Match colors will appear brighter and more saturated than on other

uncoated papers. PMS matches will be closer to the “C” value than the “U” value.

Varnishes Either varnish or aqueous coating may be used to seal the sheet. Mohawk

recommends using dull or matte varnish or dull or matte aqueous for rub protection

POST PRESS CONSIDERATIONS

***

Smooth-finish uncoated papers generally require more drying time than coated

paper. You can expect Inxwell papers to perform comparably to the drying time of other smooth-finish uncoateds.

Good delivery practices are always necessary on smooth-finish, high ink holdout papers. Spray powder is advised. Large particle size powder, 30-40 microns, will

on all uncoated papers, including Inxwell. Remember that inline varnishes will need

best separate the sheets for optimum air circulation. Running with small stacks,

Heatset web printing

Specialty processes

***

***

Paper quality and performance make or break the job and determine the profitability

suit of Mohawk papers. Mohawk’s Inxwell papers are complemented exceptionally

the same drying time as solid inks.

When it comes to paper, the needs of web printers match those of sheetfed printers. of a job. Navajo and Options are frequently recommended by leading annual report printers. They know that these papers will consistently meet or exceed the color

expectations approved by the client in pre-press and proofing. They also know that Mohawk will meet their technical demands for tight, well-made web rolls.

500- 700 sheet lifts, will help prevent ink set-off.

Specialty processes are all about touch — an attribute that is already the strong well with all specialty processes, including embossing, engraving, thermography and foil-stamping.

Finishing ***

Inxwell papers have no special requirements relating to any finishing operations,

such as die-cutting and commonly used bindery techniques. Scoring before folding, of course, is recommended for 100 text and all heavy-weight covers.

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INXWELL USERS MANUAL

: Conclusion

INXWELL CAN CHANGE THE WAY YOU LOOK AT UNCOATED PAPER. And the way printing on uncoated paper looks. When you’re ready to run your project

on Mohawk Options® and Navajo®, we’re ready, too. Together, these Inxwell® papers

come in an astonishing range of shades, sheet sizes, and basis weights. They’ve been

specified since 1995 for everything from million-copy web runs to color-copied proposals.

Best of all, they’re waiting for you — in stock at leading paper merchants in North America, Australia, Europe and Asia.

Visit www.mohawkpaper.com to learn more about Inxwell, read a few case studies, and find a merchant near you.

Production Notes This manual was printed at 175 linescreen on a conventional press using conventional inks, except for one print demo as noted. > PAPER Cover is Mohawk Options, True White 96, Smooth, 130 dtc (352 gsm). Text pages 1-24

and 29-32 are Mohawk Options, True White 96, Smooth, 100 text (148 gsm). All other papers noted on actual sheet. > INKS Cover: double hit match red, match orange, match grey, match cream, match metallic and overall dull

aqueous. Text: 4c process, double hit match red, match orange, match grey, match cream, match metallic and spot dull varnish, except as noted. > DESIGN VSA Partners, Inc. Chicago, Illinois > PHOTOGRAPHY Victor Schrager, New York, New York > PRINTING Cenveo Anderson, Los Angeles, California

Mohawk Navajo , Options , Inxwell , Mohawk and the corporate logo are proprietary trademarks of Mohawk ®

®

®

®

Fine Papers Inc. All non-Mohawk brands or product names are trademarks or registered trademarks of the respective companies.

© 2005 Mohawk Fine Papers Inc.

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Mohawk Fine Papers Inc. P.O. Box 497 465 Saratoga Street Cohoes, New York 12047 1 800 the mill www.mohawkpaper.com

DECEMBER 2005