Workshop Design Development Budaörs

Technical Concepts

Flexography One printing method with two 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 = Flexo process CMYK

12 Spot Color Printing

C M Y K Process Color Printing

Flexography vs. offset ► Register moving: 0,1mm ► Screen ruling: 100lpc/133 lpi ► Nice highlights FlexoOffset ► Register moving: 0,2-0,3mm ► Screen ruling: 24-48lpc/ lpi ► Highlights cannot be so light

Flexography vs. offset Offset Flexo

Summary Flexo line Offset/Gravure Flexo process Quality Resolution High resolution (54->) Spot color printingMedium 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 example it’s possible to visualize the results achieved in case of register variation. For this reason we do not recommend the use of positive texts, lines or outlines using 2 or more colors.

Negative Texts In the example it’s possible to visualize the results achieved in case of register variation. For this reason we do not 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 outline with 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 Process Design Hard Edge Minimum 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) FLEXO LINE FLEXO PROCESS 3. Line Thickness

Text Size

4. Trapping / Registration

OK NO OK NO Print direction % Cross direction min.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+YM+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 you have 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 & variant same colors (max. 6) ADVANTAGES: -lower order quantity -lower set up charge per order CHEAPER PACKAGING MATERIAL

Co-production 5 6 C M Y K

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!