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1. How to ensure the smooth realization of CTP system
The CTP plate-making machine, which is similar to the structure principle of the imagesetter, is no longer an obstacle to the development of CTP. One of the reasons for its rapid development earlier is that the process that is adapted to it cannot meet the needs in the past period. Digital proofing and automatic imposition are the only way for the application of CTP system. If these technologies are not really solved, the CTP system will not be developed. In other words, the development of the CTP system is not the CTP platemaking machine itself, but the process. A complete set of graphic art digital flow from typesetting to output control is the basis of the CTP system. The key to successfully implementing the CTP system is:
1). At least two years of experience in using PostScript electronic prepress systems. This experience ensures that pre-press technicians are familiar with basic file handling and troubleshooting, and can quickly identify and resolve font problems, missing images, and poorly constructed documents, etc. .
2). More than half of the work is PostScript or files compatible with PostScript format.
3). Sufficient printing consumption: A certain amount of capital is required to realize the CTP system. The printing house must consume a certain number of printing plates to get a corresponding return on investment.
4). High-quality printing plate operation: The printing house must guarantee the continuity of printing plate quality.
5). The main work does not exceed 4 colors, and the printing screen is lower than 175lpi.
6). With 6-12 months of digital proofing experience: digital proofing is one of the most controversial technologies in the CTP workflow, because it has an impact on customers and printing shops. Various digital proofing techniques need to be trained for customers and printing operators. In addition, the success of printing is also related to the company's technical staff. Their technical level and learning ability directly affect the speed of the introduction of CTP. The company needs to train such technical staff as necessary. When the server handles very heavy work tasks, it is very important to increase the number of system administrators to ensure that the server and network can operate normally. Since the CTP system affects the entire printing company, all departments involved need to undergo a series of adjustments and training.
Plate-making machine:
In terms of plate-making equipment, after several years of development, manufacturers have introduced a variety of direct plate-making systems that are mature in technology, can be automatically plated, can handle different specifications and different types of plates, and have greatly increased plate-making speed. For example, the prestigious Quansheng 3244 series, there are already thousands of Quansheng series computer direct manufacturing machines operating successfully all over the country. It uses a new 20-watt thermal laser head, a unique SQUARESPOT square photosensitive imaging technology. Won the GATF Technology Award of the American Printing Technology Foundation five times, enjoying a good reputation in the field of computer-to-plate, and rapidly expanding into the field of digital offset printing. Built-in laser cooling system and debris collection unit (for ablative no-rinsing printing plates, with a proven outer drum design, the drum rotates at a constant speed during exposure to ensure stable and consistent imaging. For accurate registration, use A unique temperature compensation system is provided. During the imaging process, it can adjust and compensate for the thermal expansion and contraction of the printing plate due to changes in the ambient temperature, ensuring that the same machine is at different times or even different printing plates. Can be accurately registered, exposure is stable and consistent and repeatable.
CTP plate material:
The key to the technology of computer-to-plate is that the printing plate and the imaging system must be matched. Silver salt plate material: high sensitivity, high resolution, high printing resistance, must be operated under a safety light, and the exclusion of silver salt in the process must be properly handled. Photosensitive resin plate: similar to ordinary plate, it must be processed in water-based chemical composition. However, compared with the silver salt version, the sensitivity, resolution, and print resistance of the photosensitive resin version are very low. The use of a new high-sensitivity resin emulsion can ensure the consistency of the product and the stability of the graphics-this is also the most important consideration when choosing the plate material. Mixed plate: Add the low-sensitivity silver halide mask layer in the exposure process to the ordinary photosensitive emulsion, so that you can get the advantages of the two materials after the compromise. However, this mixture requires a very long plate-making production line and two cost-removal channels, as well as a more complicated manufacturing process. Thermal plate: It can be operated in daylight, high-resolution replication, accurate imaging, and the potential to simplify the process. Plate, film, proofing can be imaged on the same device. However, the thermal technology is not as mature as the visible laser system, so the thermal selection is very limited, and the thermal technology still has potential to be tapped.
2. Common problems and solutions when using CTP
The maturity and development of CTP technology has brought different production benefits to manufacturers using it. In the face of new technologies and new processes, due to the operator's experience or pre-production documents and other reasons, there are often problems that need our attention in actual work.
1). Size problem
(1) The size of the created file does not match the actual required size.
(2) The amount of bleeding required was not taken into account when preparing the document.
(3) The text or image is too close to the finished cutting line.
Solution:
(1) Define "Document Setting" / "Page Size" as the finished size.
(2) The amount of bleeding on the page should be considered when creating the file, which is generally 3mm.
(3) The distance between the text or image and the finished cutting line is at least 5mm, preferably more than 8mm.
2). Image problem
(1) RGB images are used for color images or graphics.
(2) The image accuracy does not meet the basic requirements for printing, such as the resolution is too low.
(3) The information compressed in the JPEG format, the level, details is lost.
(4) The image is not retouched after electrical distribution or scanning, leaving dirty spots on the image.
(5) An error occurred when linking or re-inserting the image.
Solution:
(1) The design and production personnel are required to have the most basic understanding of conventional printing knowledge, and possess certain aesthetic knowledge.
(2) Realize the management standardization of CTP system. Standardize the process and clarify the requirements of each process.
Recommended practice:
(1) There are basic requirements for the quality of color separation images.
(2) CMYK color mode is generally used during printing.
(3) The image must have sufficient accuracy. For large images, the resolution of color images is usually 300dpi or 350dpi, and the resolution of Bitmap images is usually 1200dpi, at least 800dpi, so as to avoid aliasing.
(4) The electric time-sharing setting should be accurate, and the file should be able to faithfully reproduce the original, with high definition, rich details, and good level.
(5) Repainting is required for color correction after electrical separation to avoid leaving dirty spots.
(6) Do not compress images as much as possible, especially images compressed in JPEG format cannot be used for printing.
(7) Standardize file naming to avoid the appearance of files with the same name. Be careful when re-linking images, if something goes wrong, it will be fatal, so do n’t take it lightly to avoid serious damage.
3). Font problem
For fonts that are not in the PS font library, especially Chinese fonts, Truetype fonts are generally used for downloading, but it is easy to produce missing or shifted characters.
Solution:
(1) Purchase the corresponding PS font or CID font.
(2) Install commonly used fonts for the CTP system and require customers to use the fonts of the corresponding fonts.
(3) For the missing fonts, you can consult with the customer to replace it with a similar font, but pay attention to the shift of the word; you can also ask the customer to provide the font, especially the foreign language.
(4) Use â…¢ustrator, FreeHand or CoreIDraw and other software to convert the font into a curve and save it as an EPS file format for image processing.
(5) For K100 fonts, trapping is generally done.
4). Spelling problem
1. For books of smaller sizes, double copies or multiple copies are generally used for printing, but if the text is arranged in double copies or multiple copies, and the cover or backing paper is arranged in a single copy, it will be easy to make mistakes when making large editions Add a larger workload to binding.
Solution: The entire book (including the inner text, cover and backing paper, etc.) is arranged in double or multiple copies, and the gap between them should be consistent.
2. For printed products with overlapping printing, the printing characteristics are not taken into consideration, and the printing requirements are not met. For example, the printing of live parts with large differences in colors is printed together.
Solution: As far as possible, arrange similar-colored prints in the same ink path.
3. For a series of multiple packaging boxes of the same size, when two or more plates are overlapped, it is often the case that each large plate has to be made a knife mold due to different gaps.
Solution:
(1) Use CAD software to make the die line, and then make a large version according to the die line to ensure the sharing of the die line.
(2) The different spellings of the large version have different effects on the quality and efficiency of printing and binding. The optimal scheme can make the post-process complete successfully, and the failed spelling will bring unpredictable troubles to the post-process. Unable to complete the work, or even have to rework. Therefore, the operator of the layout should be familiar with the pre-press, printing, and post-press processes, and it is best to have someone to check the quality.
5). Output problems
1. When printing a PS file or a PDF file, if the color separation mode is selected, it will cause inconvenience to modify the PDF file.
Solution: Use composite color output.
2. For multi-language version books, most of them are K-color editions, and C, M, and Y-color editions are shared, or four-color editions are shared and spot color editions are used. In actual operation, confusion is easy to occur.
Solution: Use text at floating mouth or ridge code. Icons or colors are used as logos for different versions to avoid confusion.
3. File updating is the most common and deadly problem. If the modified application file is not updated in a blue paper or large-format file in time, the old file is used for direct plate-making, and the old content is still printed.
Solution: This is a management standardization problem of CTP system. The key to solving this problem is to formulate a reasonable and standard working process of the CTP system, strengthen the standardized operation of employees, and realize barrier-free communication between employees.
6). Color management issues
Color management is the focus and difficulty of CTP technology. The ICC characteristic curve that accurately reflects the characteristics of the device determines the effect of color management. Therefore, the generation of ICC characteristic curves has become the top priority of color management. In production practice, the author summarizes the following points to be noted:
1. Try to keep the printing in a stable state. Enterprises should establish a set of effective printing standards, especially in terms of controlling printing density and dot gain, and require operators to resolutely implement in the printing process to control various indicators within the error range.
2. To ensure that the digital proofing equipment is in a normal state. For example, Agfa ’s Sharpa series can use QMS (Qualiy Management System) software to detect and adjust the machine, so that the digital proofing equipment is always in a normal state, and the printing effect is consistent.
3. The surface of IT8 for measurement must be clean, free of oil stains and creases, which has an important impact on whether the ICC characteristic curve can accurately reflect the characteristics of the equipment.
4. In theory, different printing conditions correspond to different ICC characteristic curves. However, for common prints and the general visual perception of the human eye, for the three commonly used papers: coated paper, matt copper, and offset paper, set three ICC characteristic curves that reflect their printing characteristics.
5. With the continuous development of technology, color management software should also be continuously upgraded. From the information feedback from the client, ColorTune used with the Agfa CTP system is upgraded to version 4.2, which not only can accurately simulate the printing effect, but also is very stable, and the color management effect has achieved a qualitative leap.
7). Printing problems
The current CTP system is generally used by large and medium-sized printing enterprises, most of them have a few. A dozen or even dozens of different types of printing machines, such as Heidelberg. Manroland, KBA, Mitsubishi, Beiren, etc., there are both single-sided printing machines and double-sided printing machines, as well as sheet-fed printing machines and rotary printing machines. On the one hand, the size of the plate material used in different models will be different, and the layout of the single-sided printing machine and the double-sided printing machine will also be different; on the other hand, for the CTP system, once the blue paper is confirmed You can output printing plates. In fact, unless the printing is completed, the printed matter may be printed by different printing machines. In this way, it can be prepared in advance, and will not cause waste for some reasons.
The printing plate of the double-sided printing machine can be transferred to the single-sided printing machine for printing, but not vice versa; the large-sized printing plate can be cut into a smaller-sized printing plate, and then printed on the small-format printing machine, otherwise it is not. Based on the above two points and the actual situation, considering the flexibility of production scheduling, it is necessary to pay attention to the following two points: if the paper is large enough, it should be as large as possible according to the double-sided printing press; Large size printing plate, otherwise it will bring unnecessary trouble and loss to production. In addition, pay close attention to the inspection of blue paper, most of the errors can be found on the blue paper. As the managers of the CTP system and related practitioners, we must attach great importance to the inspection of the blue paper, achieve multi-layer inspection, check carefully, and minimize the error rate.
Nowadays, the development of CTP technology is changing with each passing day. We need to analyze specific problems in the process of continuous learning and exploration, and there are no ready-made formulas and rules that can be copied. CTP technology has many skills. Learning and applying these skills will greatly improve work efficiency. Operators engaged in CTP work must understand the process and technical requirements of the previous and subsequent processes, otherwise they cannot judge the correctness of the work; managers engaged in CTP work should be proficient in technology and use various management knowledge in the complex and complicated work Coordinate the overall situation, master and control the work process, and make the work proceed in an orderly manner.
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