1. Printing
Brian Russell

2. Exam expectations
Paper/card is the compulsory material so always expect questions in exam to relate to this topic. Questions on printing usually link to packaging.

3. What do you need to know?
At the very least you should be able to name a commercial printing process and explain why it would be chosen
It also links to other manufacturing questions

4. Commercial manufacturing
Typical order of work:
Finishing – print, varnish, emboss…
Wastage/separation – die-cut/crease
Forming - folding
Assembling – glue, inserts…
This order is different from many manufacturing processes

5. Commercial Manufacturing
Typical litho presses set up for 4 process colours, a spot colour and varnish in one continuous cycle
Typical folding machine for small cartons

6. Commercial Manufacturing
Typical rotogravure printing presses set up for 4 process colours, metallic spot colours and varnish in one continuous cycle
Typical flexographic press used for printing plastic film

7. Printing card Typically offset lithographic or gravure process used
4 process colours – yellow, magenta, cyan, black
Varnishing, foil blocking, embossing are common

8. Offset lithography Flat aluminium plates (specially treated)
Photographically exposed then wrapped around roller
Exposed parts attract water
Non exposed parts allow ink to stick
Print onto plain roller to reverse image
Transfers to card or other materials

9. Gravure Printing Used for very large print runs Uses engraved plates
Ink is held in recesses known as cells
Paper is pressed onto plate and ink is lifted from cells

10. Rotogravure Presses
Cylinders are placed in line with a heater between each one to dry the ink

11. Flexographic printing
Uses a printing plate made of rubber, plastic, or some other flexible material.
Ink is applied to a raised image on the plate, which transfers the image to the printing

12. Printing terms
Process colours – yellow, magenta and cyan make full range of colours, black adds definition (and text)
Spot colours – mixed to exact colour
Web offset – printed onto a roll (e.g. newspapers)
Plate – has the image on, wraps around a cylinder
Offset cylinder (or blanket cylinder) – reverses image
Impression cylinder – presses paper onto plate
Varnish – adds shine (or could apply a matt finish) to print, sometimes in isolated areas
Substrate – material to be printed e.g. paper

13. Other related processes
Die-cutting is the method most paper/card shapes are cut out. In the packaging industry the cutter is known as a cutting forme.
Foil blocking is a method of applying a very thin layer of metal foil onto the surface to add a special effect
Embossing is the method where the surface of the card is pressed upwards to create a special effect

14. A few exam tips
Offset lithography is the best answer for any questions relating to the printing of card packaging
Flexography is the best answer for any question relating to the printing of plastic film (such as carrier bags)
Printing is a finishing technique suitable for card and some other materials