TECHNIQUE, SOLUTION, EXPERIENCE FOR GRAPHIC DESIGNERS & PREPRESS MANAGERS EDITION 05 | JANUARY 2023

PANTONE
And Colors That Can
Change At The Time
Of Printing
Why Do Pantone Colors Change?
Reducing Logistics Costs And The Role Of Designers In It
Packaging Engineering Basic Principles
Finding Minimum Dots In File And Solving Their Problem
Dot Philosophy Challenging Press

WWW.PREPRESSMAG.COM INFO@PREPRESSMAG.COM ALL OF THE INFORMATION IN THIS MAGAZINE ARE RESERVED FOR THE “PREPRESSDAILY” GROUP.
 Editor’s Note

Welcome to the fifth edition. One of the prominent points that

graphic designers should pay attention to is issues that happen
outside of the design field. You have always been introduced
in the field of design, you have discussed your ideas with the
employer and finally, you have checked the product market
according to the ideas of other competitors, but are these things
enough for a successful production in the marketing path?
We must say that everything that happens during the production,
marketing and sale of products is related to graphic designers
in some way. But these items need to be checked and more
carefully by the designers. You can help reduce production
time by calculating the dimensions of the file when defining the
package, and even make it profitable. What can make you an
outstanding designer is your attention to all the principles that
exist in the field of packaging.
In this edition, we will talk about these topics to clarify the path of
becoming a professional.
ON THE COVER
We eagerly anticipate your feedback and your articles to be “Pantone is a reputable
published in the magazine. company known for
producing accurate colors
Reza Alee - Editor in Chief for printing. The color
of the year is proposed
by this company called
PREPRESS MAGAZINE TEAM Magenta. This color can
Director & Founder: PrepressDaily Group be used as a reference for
Editor in Chief & Art Director: Reza Alee designers and is defined
Design, Layout: Emir Ölmez, Mehmet Akkoyun according to various
Contributors: Olga Afşar, Atiye Aykoç, Biret Erkoç criteria. Fashion designers,
Media Marketing: Edward Olins graphic designers and
Translators: Shaqayeq Fattahi, Parto Ghahramani, Samira Afghari people who are active in
Image Credits: pixabay.com, unsplash.com, freepik.com the field of decoration use
the color of the year as a
symbol in modern design
PREPRESS, A Specialized Digital Magazine About Prepress and give more credibility
On The Subject Of Graphic File Reproduction, Color Management & Preflight to their activity. but this is
www.prepressmag.com | info@prepressmag.com not the whole story...”

“PrepressDaily” Group is a progressive startup active in standardizing graphic files for the commercial printings purposes such
as Flexo, Offset, and Gravure prints. “PrepressDaily” Group is an independent institution, which has no political or religious
orientations. “Prepress” is the official title of the “PrepressDaily” Group’s magazine aiming to provide and publish information,
resource, and technology for optimizing the printing products.
All rights reserved: All of the content, logo, layout and information in this magazine are reserved for the “PrepressDaily” Group.
Copying and sharing in any kind without the permission of its owners is strictly forbidden.
 Prepress Magazine

10 Why Do Pantone Colors

Change?

22
Reducing Logistics
Costs And The Role Of
Designers In It

30 Packaging Engineering
Basic Principles

38
Finding Minimum Dots
In File And Solving Their
Problem

44 Dot Philosophy
Challenging Press

58 Questions & Answers

About Your Requests
 digital edition on iOS or Android

You can download

previous editions of the
Prepress magazine in high
quality PDF format from
the official website

www.prepressmag.com
 We want to publish PREPRESS
magazine in languages other than
English. Translation into a new
language will be done by giving
representation to some teams.
In this direction, we are waiting
for your suggestions.

info@prepressmag.com
 Why Do
Pantone
Colors
Change?
by Prepress Magazine Team

Pantone is a familiar name in the ink and printing

industry. This company with the help of research
and scientific support has been able to work well
in the printing industry, ink making, fashion and
even advertising. The color of the year is regularly
selected and announced by Pantone. Color books
are published for graphic designers and various
events related to creativity and advertising are
held by this company.
One of the most important activities of Pantone
company is production of a variety of color books
created for graphic designers and creative managers.
In these books, different colors are offered for
printing, according to each book, its ink is also created
for printing. The final inks quality is very high and
each color has its own code and formulation; but
does each color reach the production stage exactly
according to what is in the book?

10 PREPRESS | EDITION 05 | JANUARY 2023

Most of the people in graphic
design world use spot colors
to match colors at printing
time. This set of colors is
made and enters into the
printing machine directly to
minimize the possibility of
color change during printing.
In contrast to Spot colors,
there is a set of mixed colors
or CMYK which is defined
and made by the four main
printing colors, called Cyan-
Magenta-Yellow-Black.
At first, we will discuss how
to use CMYK colors and after
comparing with Spot colors,
we will come to the issue of
changing Pantone colors.
 Files that are sent for
printing have a famous
color model known as
CMYK. This means that the
designed file is ready for
printing However, it can
have besides CMYK, other
colors inside it. In print files
you can even put different
images with different
color models such as Gray
or Multichannel. But the
point is, where is the main
difference in using CMYK
and Spot colors?

Are spot colors a subset of

four colors? Can a CMYK
file have a new color model
due to the presence of spot
colors?

And how the color selection

theory was able to create
the CMYK model & where
are spot colors defined in
this theory?

in their color model or composite structure?

12 PREPRESS | EDITION 05 | JANUARY 2023

According to color theory in printing,
three main colors of CMY can be
combined by different percentages
and create new colors. Next to these
three colors to create pure black,
black was also added to the collection
to increase the variety of dark colors.
Designer can also design to create
black. For example, look at these
codes which in combination together
create dark red:

C: 10% M: 90% Y: 100% K: 20% Colors definition by CMYK

Correct production of this color at system is inexpensive but
printing time depends on appropriate
density of CMYK colors. This is why a
achieving an accurate color
graphic designer defines a color code with this system usually
requires its own financial
but at the time of printing, different
results are obtained because you only
define a color code on the file, but the
density of each ink can be changed at resources and time.
the time of printing and the result will be
different reds in several times of printing.

Ink density checking to receive

a standard process by CMYK is
possible, but Densitometer accurate
tool and implementation of color
management structures are also
required. In addition, you should also
use appropriate Color Bar at printing
time. In this way the density of inks
entered into the printing machine are
defined by a specific criterion and they
can be controlled.
 But the control of the
mentioned points is
usually not done for
these 4 reasons:
1- Tools cost: Special devices such as Densitometers
and even Spectrophotometers are used to accurately
determine the density and its volume on the printing
material. This tools are expensive and usually printing
houses do not prepare them.

2- Color management knowledge: When we want to

measure the amount of ink, the operator must have a
good knowledge of the color structure, printing machines,
Color control on Palte and be able to modify it. Learning
this knowledge is also time consuming and costly.

3- Machinery: In color control process, the inside

equipment of the printing machine also must be adjusted.
Sometimes it is necessary to replace some worn parts or
the device should be adjusted according to the type of ink
and printing material and this process is not always done.

4- Timing: Sufficient time is also required to create proper

production. Prepare standard color samples to matching
the device or Fingerprint has its own time and costs. Some
printing houses do not do this process.

Only a few printing houses are very

active in providing accurate color
control tools and Equipping printing
machines. For this reason, they also
produce accurate colors with the
CMYK system.

14 PREPRESS | EDITION 05 | JANUARY 2023

 C: 10

M: 90

Y: 100

K: 20

The opposite of CMYK colors is the Spot colors set. These

colors enter the device in a pre-prepared way. That is, the
graphic designer defines areas as Spot colors on the file, and
that color enters directly into the printing machine.

Suppose, like the previous example, we need a surface of

red color. We define desired areas as Spot and this color
enters directly into the printing machine. In this example, a
combination of CMYK does not happen because the color is
ready. Spot colors require less control, because the color is
prepared before printing and the probability of changing the
density is low. Their quality is higher than CMYK and they
usually do not have the problems of the previous case.

But why can’t we always

use Spot colors?
 Spot colors are created in two ways:
First) By printing house officials who create one color by
combining several colors and according to the customer’s
needs.

Second) By reputable companies such as Pantone that use

special formulations to make high quality for final colors.

In the first case, printing house achieves new combinations

of the desired color with the different colors it has. Because
there is a possibility of error in it, this combination must
be done carefully and a supervisor must check the final
production color. All the Spot color production processes are
usually done in printing house traditionally and by Manual
combination. The accuracy of the final color is not very high,
but anyway, a proper color for printing has been created.

In the second case, when reputable companies produce

paint, the color formulation is predefined. Each color has its
own code and very professional expert create its color and
formulation. This is also a kind of Spot color but more accurate
than first case. It also has higher quality and cost.

Reputable companies like Pantone

that produce Spot Colors have a
very accurate formulation to create
quality colors. For this reason, both
the quality and the price of the final
color are high.

16 PREPRESS | EDITION 05 | JANUARY 2023

Pantone colors under specific condition offer very good quality. Color
saturation is very high, their change in high circulations is very small and
they will have the desired result for the employer but this is not the whole
story. Different conditions can make problems even for these colors. It
should be remembered that various parts in the printing machine are
parts of production process. Blanket – Cliché – Anilox – Plate and even
thickness of printed material must be pre-defined according to the type
of Pantone color.

Example in Flexo:
In this printing machine there is important part is called Anilox. This
cylinder is responsible for transferring the ink to the Cliche. If the holes
on the Anilox are larger than necessary, more ink enters the printing
system and the file shadows get in trouble. It does not matter if the input
color is CMYK or Pantone. Of course, it is easier to control Pantone, but
sometimes the amount of ink is so high that it is not possible to have
precise settings.

Example in Offset:
Suppose your printing material is LWC. This title refers to very light paper
used in newspaper printing. Pantone color due to its special quality and
formulation takes special time to dry however, LWC is very thin and the
drying process is slow. In this case Pantone color by passing through
warp and woof of paper goes to the other side and it may affect other
colors as well.

The type of printing machine, the material

chosen for production, the time required
to implement the production process and
comply with the production standards can
change the color of the print.
 Sometimes Pantone color book creates the problem. As you know, Pantone
Company has produced color books with various titles such as Solid Coated-
Uncoated to match colors accurately at printing time. These books lose their
quality over time due to light and moisture. When a graphic designer chooses
a color based on an existing book, this loss of quality can also cause problems
in production.

Other reasons for the change in Pantone colors include equipment and
machinery. Different components of the printing machine, if worn, can cause
various changes in the color printing process. Therefore, even if Pantone
colors are used, the quality of printing machines, the humidity of the printing
house and even the speed of the machine must be in harmony with the type
of production. These cases can be checked and corrected by the guidance of
the production manager or quality control manager.

Keep in mind that Pantone is a

reputable company in the production
of Spot colors but these colors can
change depending on the quality of
printing machines and materials.

18 PREPRESS | EDITION 05 | JANUARY 2023

There are several suggestions for improving print quality using Spot
colors produced by the printing house or Pantone:

Avoid using old coloring books that have changed over time.

Get the information you need from the printing production manager
about whether the printing material matches the ink type.

Make sure that the printing machine is not worn out and even the
printing press environment has adequate humidity.

From the Pantone color digital books available in the software, just
select the color with the physical book.

Keep your monitor in calibration mode but never trust it completely

because monitors can display colors incorrectly under different
conditions.

Make sure the Pantone colors you buy are original.

Finally, the color of the year was chosen by Pantone. Whether the
idea of choosing this color is right or not! how many interpretations
are correct for using artificial intelligence in choosing this color!
or whether the color of the year can play a role in the world only
because of Pantone’s suggestion!

These are the talks we are waiting to hear...

WWW.SIGMAPACKPRINT.COM
 Reducing
Logistics Costs
and the role of designers in it
by Prepress Magazine Team

Have you ever thought about how graphic designers

can play any role to reduce logistics costs at the time
of prepress? Usually, when it comes to packaging,
the cost of logistics becomes very high in a one-year
period, and production managers seek to reduce these
costs in some ways.
But part of this reduction is done during prepress by
designers who come up with ideas and also designing
structures are important. Although it is not always
easy to talk about cost reduction, but as an important
issue, we can try to control and check them.
In this section, some points are mentioned for
packaging graphic designers and can help the
employer in the field of production.

22 PREPRESS | EDITION 05 | JANUARY 2023

 The structure is repeated several times on the
print form. This process is called Imposition.
Finally, part of the form is completed and part
of it is left blank. The blank part is known as
waste paper. If the packaging designer knows
the size of the printed form, he can resize the
structure to reduce that waste. Sometimes
the dimensions are so inappropriate that the
number of structures in the form is reduced. It
should be noted that the size of the structure
can be compared to the size of the printed form
in order to create the least amount of waste.

Of course, it is not always possible to change the

dimensions because sometimes the employer is
not willing to change the packaging dimensions
and creativity is his priority.

Reducing production
costs in the first stage
can be done during
prepress by modifying
the dimensions of the
structure compared to
the printed form.

24 PREPRESS | EDITION 05 | JANUARY 2023

In the next step, attention should be paid to the
dimensions of the produced packaging compared
to larger shipping cartons. A number of products are
placed in Base Carton. These cartons are made as
Corrugated Flute in different thicknesses and have
different standards. Companies like FEFCO have
developed all the necessary rules and standards for
these cartons, and this section can be effective in
reducing costs as mentioned below.

A number of packaging products are printed and

produced. These products should be placed in
the Base Carton in an appropriate amount. In this
section, the production manager or graphic designer,
before any other process, must calculate how many
of that product would fit in the shipping cartons in
the current dimensions of the packaging. Sometimes
more can be fitted in Base Carton with very little
reduction of primary packaging.
Assume that this process does not take place. Which
means the dimensions of the product are not be
checked with the number of arrangements in the
carton. Most likely, there will be more products
so more cartons should be prepared to arrange
them. And this means, both reproducing the Base
Carton and printing on it, as well as re-providing
the transportation machine and thus increasing the
overall logistics costs.

Cost reduction does

not end there and
can still be explored.
 Here there is another point you need to know. Some products need to be arranged
on a pallet due to the high number of Base Carton and of course more weight.
These structures are used for transportation in warehouses, cars and even transfer
with Pallet Truck devices.

When the number of Base Carton is arranged on Pallets, the best way is to define a
specific and optimal number so that less pallets are used and less time is spent on
logistics.

The point is that if the packaging products are not placed in the Base Carton from the
previous steps, how can they be placed on the Pallet?

The logistics costs should

be controlled according
to the transport vehicle,
pallet and base carton,
and these items can be
checked by defining the
basic structure of the
packaging.

26 PREPRESS | EDITION 05 | JANUARY 2023

Everything
starts with
the structure.
The logistics
costs should
be controlled
according to the
transport vehicle,
pallet and base
carton, and
these items can
be checked by
defining the basic
structure of the
packaging.
 In a final summary, we complete this section There are 50 pallets inside each transit transporter,
with an example. The basic structure of the and including all the mentioned items, 1500
graphic designer is defined regardless of extra packages will be left in each transport.
the imposition and formatting of the print. 3
millimeters on each side of the production Now, to move 1500 small packages, 115 new
waste is created. Base Carton orders must be created, and this
means 3 new pallets and transportation costs
This amount is a total of 12 millimeters on the that must be recalculated.
four sides of the package. This small amount
makes the arrangement in the Base Carton See here that all the mentioned items and these
become 13 instead of 14, and each carton will numbers are for the small one that the designer
have 1 extra package. prepared without regard to the formatting and
the transportation system and only based on
30 cartons can be arranged on each pallet, creativity and besides, the costs of manpower,
and with extra packaging, there are 30 extra waste papers and new technical calculations
packages in each pallet. should also be considered.

28 PREPRESS | EDITION 05 | JANUARY 2023

 Packaging
Engineering
Basic principles
by Prepress Magazine Team

When it comes to packaging and Production, a lot

of information should be examined. They include
graphic design, printing, structure, ink density,
production timing, use of special techniques during
printing, scan images and many more.
Together, these items make a more comprehensive
concept when they are classified and registered
according to employer needs. It means that the
complete path from design to production can be
specified in a file. The need for correct production is
determined through this file, which we call “Package
Production Identity”. Each packaging needs a correct
definition according to the type of production for a
brand. These definitions act as product handbook
so Packaging production will proceed with higher
accuracy by these definitions.
In the following, you will get to know a little about
the “Packaging Production Identity”.

30 PREPRESS | EDITION 05 | JANUARY 2023

Suppose that a packaging design in CMYK with two Pantone colors is
done and the final file includes six colors. There are many illustrations in
the file. All colors have been corrected and there are images in the file.
This file must be printed by a Flexography machine. After the design,
the production manager announces his/her opinions and needs to the
printing house therefore package production path can proceed correctly.
These comments can include these points:

The ink density should be such that the color is printed as Rich Black.

The amount of bleed in the file is defined as 3 mm.

Pantone colors as Gold – Silver are defined by specific codes.

Dot Gain=10% is defined in the color profile.

The ink standard on the file follows the Euro settings.

Cyan should be defined as 55.9/-21.9/-47.9 in the L*a*b* system

Distortion factor is defined as 3 mm.

* This list includes other items as well which can even include the type of
paper and paper grammage.
 An example of a Packaging Production Handbook, provided by sigmapackprint.com

The issue is that the designer or the Packaging handbook preparation can
production manager must express determine the entire production path
all these points to the printing house for managers. Of course, sometimes
orally. At best, these may be simply the production of this handbook is
typed on paper. But is this process time consuming and maybe it is not
correct for packaging production? Is suitable for ordinary packages that are
it possible to complete the production supposed to have a low production at
with these short tips? What should be a low price. But when it comes to big
done if the printing house changes or brands, creating this handbook can
the printing house manager makes a improve the production process and
mistake in receiving the information? prevent various mistakes.

When it comes to the special planning

called «Packaging Production Identity»,
The purpose is to record complete
information in the production path, in the
form of a «Handbook» which is considered
as a common language between the
designer and the printing house.

32 PREPRESS | EDITION 05 | JANUARY 2023

 An example of a Packaging Production Handbook, provided by sigmapackprint.com

Suppose that designed file is produced in

ways such as sending messages on WhatsApp,
talking on the phone or writing short details in
the contract. But if the printing house changes
or the person responsible for production
resigns from the company, again, the entire
production process must be reviewed and
performed with the new person in different
meetings. This process leads to the loss of time
and human energy, which can be avoided in
new management methods.
A packaging handbook
can reduce time and
energy spent during
A suitable solution production and easily
increase the printing
accuracy of the final
The best solution is to mention the entire product.
production process in the packaging handbook.
Of course, the comprehensiveness or summary
of this information completely depends on the
amount of production, management attitude
and market needs. This process includes
instructions for printing to avoid talking on the
phone or sending back-and-forth messages
during production. Through this method, all
production managers use the same method
for printing, and in their absence, the printing
house can also use the information mentioned
in the handbook. Of course, the presence of
a print supervisor and production manager is
always necessary to make communication and
correct very specific points.
 In the following, we mention some points about
packaging handbook. But note that this handbook can
be defined to the same extent for several products. For
example, when a product is printed in two different
dimensions, but the rest of its design and printing
points are the same.

01. Structure section

Accurate determination of dimensions, angles and
diecut in the current packaging structure.

Defining the location of glue and the empty space of

glue in the hard box packaging.

Standard definition similar to FEFCO or ECMA code if

there is a structure in these standards.

Determining order and priority of folding and closing

the product in the carton packaging.

02. Color section

Definition of different allowed colors and distance for
barcode to correct reading of barcode reader.

Braille definition for the blind according to the ECMA

standard for carton boxes.

Preparing the exact CMYK color code used in the file

based on the color profile.

Determining Pantone color code based on CMYK

color type for carton and glossy material.

Determining the L*a*b* color code of Pantone inks to

use in the color management system.

Determining the L*a*b* color code of CMYK brand colors

to use in the color management system.

Determining the ink code in the structure of Yxy or

L*a*b* coordinates in the color management system.

Determining the amount of packaging ink used for

each product to control the quality of printing.

34 PREPRESS | EDITION 05 | JANUARY 2023

 03. Print section
Definition of the closest pantone colors with minimum
dE for color management system.

Preparation of maximum TIC color coverage for final

CMYK colors to create color profile.

Determining the color profile according to the type of

material and printing machine (flexo and offset).

Calculation of shades of grays equivalent to color in

pantone or spot.

Although the mentioned sections can change for each

package, but they can be modified according to the
needs of the employer. You can add other sections
such as Lithography, Binding and Color Management
to it and mention items for each section.

Each item can be created either as a summary or with

explanations for the production manager. The purpose
of creating a handbook is to define a fixed process for file
output, standard printing, and production path when the
team members change, the printing house changes, or
even in the absence of the previous production manager.

Preparation of this handbook can be done in a few hours

for small packages and in a few days for more special
products. But the value of this notebook is determined
when you want to do the printing process in any printing
house with a fixed method. In preparing this handbook
use the graphic designers who had the task of ideation
and creation of the initial design and asked about Color
Channels, Color Separation or Resolution. Other persons
who may assist in the completion of this handbook may
Q.C. Manager, Production Manager, Printing Operator or
Lithography Operator and each of them will provide the
necessary guidance if needed.
As a printing supervisor, prepress
manager or graphic designer
that deals with preflight and
color adjustment, you can have a
interview with us and introduce
yourself. The challenges you have
had can be interesting for readers.
info@prepressmag.com
 Finding
Minimum
Dots In File
and solving their problem
by Prepress Magazine Team

Although the technology of printing machines

is improving every day, but we must always be
careful. Sometimes very light colors do not transfer
properly on the plate. Minimum dots mostly occur
on Flexo and Cliche printers, but you can check it
for any other commercial printing press. Graphic
designers can find them on digital files and fix them
with different techniques. To create a quality print
in which all colors are created correctly, consider
reading this article carefully.

38 PREPRESS | EDITION 05 | JANUARY 2023

As you know, all the elements in a
graphic file are converted to dots in a
section called Lithography. These points
form the structure of your printing file.
They have a certain size and are created
in a certain density. The ink is placed on
these points and finally, it is transferred
to the printed material or substrate by
pressure. This paragraph gives you a
brief overview on production process.
But where is the problem? The points
are always at risk. If they are not in the
right position in terms of size, angle and
position, there will be errors in the result
and one of these errors is the removal
of very bright colors in lithography or at
the time of printing.

* Note that the digital file consists of

pixels or vector lines, and the halftone
dots are created after the file is
converted into lithography. But some
halftone points that may be removed
in the print are part of the colors, and
you can check their color code on the
file and help the print quality.
 The first case
Although with the advancement of technology, the
accuracy of plate preparation has increased, but still
in some cases, the minimum dots of less than 3% can
cause printing problems. Here is an example: When
you are designing a catalog or illustration, there is a
shadow in a part of this design that starts from zero or Minimum Dots in Rip
white and continues up to 100% black. This shadow
can be seen on the monitor in Smooth mode and there
is no problem. You save the file as a PDF and submit
it to Lithography. There, for various reasons, colors
less than 3% are not printed on the plate and you lose
some very bright colors when printing. Missing some
colors during printing is known as a Breakout. Light colors in file

The loss of some colors due to

Minimum Dots can be discussed
in two parts: As mentioned, the
first, the dots do not appear in
lithography. Second, there are
dots on the plate but there are
problems during printing.
Original picture

40 PREPRESS | EDITION 05 | JANUARY 2023

 The second case
Keep in mind that your file is defined by a number of
points according to the LPI. That is, the designed file, Dot Dipping
including the Vector and Pixel elements, becomes a set
of points with your chosen resolution. This set of points
has its own resolution in lithography and is expressed
by the LPI criterion. In Flexo printing, there is a unit
called Anilox, which contains various holes in which
there is ink. Cliche receives the ink from Anilox and
transfers it to the printed material. Now what happens
if the size of your dots is too small for the LPI and the
dots’ tops enter the holes filled with Anilox ink? In this
case, the amount of ink placed on very small points, The initial identification
will be more than necessary and you will lose subtle
shadows when printing. and modification of
Insertion of the top of the dots into the holes of Anilox Minimum Dots can
during printing causes the disappearance of very bright
colors and is also known as Dot Dipping. This is due to
be done by graphic
the LPI difference between Cliche and Anilox. This is designers and on digital
beyond the scope of a graphic designer and should be
considered at the time of production. But know that one files to prevent future
of the solutions to this problem is that the production consequences and
manager should divide the amount of Anilox LPI by 6
and select the resulting number as the LPI for Cliche. production problems.
 Solutions
in the first case and on the digital file, if you design in
Vector programs such as Adobe Illustrator, you can
check and change the colors to correct the Minimum Esko Viewer
dots. Of course, it is better to first ask Lithography
about the numbers needed for minimum dots.
Now check your CMYK code in the light colored
sections and correct the color if necessary. A more
professional solution for checking all file colors is to
use the Esko Deskpack and the Viewer command in
the Esko>Viewer menu. In the command panel, select
the Breakout option and enter the desired percentage.
Objects that have less color than mentioned will be
highlighted. This panel even finds the necessary points
on the images.

There are several ways to edit images in Photoshop.

You can also use EskoDeskpack. In the Filter menu, run
Deskpack and then FlexoClean. There are many options
in this window. By modifying the value defined in
Cut Off Highlights, you can convert all very bright colors
to a certain percentage. For example, all colors less than
three percent are converted to a number above three
percent. With the Cut off command, you will fill part of
the minimum dots with a higher percentage of color.

Esko FlexoClean
Because ESKO software is so
expensive, you may not have it
available. In this case, you can
try other ways in Photoshop.
One way is to use the Curve
command.

42 PREPRESS | EDITION 05 | JANUARY 2023

Open the Curve command
window by pressing Ctrl+M.
Activate the Pencil tool in
this window and enter the
top of the matrix. Hold your
mouse where Input=3 and
Output=100. Of course, the
amount of input depends
on the Minimum Dot
announced by Lithography.

Now draw a straight line to

the left with the pencil tool
very carefully. If you follow
all the steps correctly, part of
your file will be highlighted
in black.

In the last part, place the

pencil tool at the bottom
with the specifications
Input=0 and Output=0 and
drag to the corner of the
window, this way, the white
parts of your design will
return to the original state
and only the Minimum Dots
Will remain.

In the Curve command window, you can also activate the Channel section from the beginning and
select your color channel where you want to check the points only from. After identifying the sensitive
points, you should correct them, which of course will be discussed in future volumes of the magazine.

Keep in mind that an important part of the production process

can be reviewed and modified in the Prepress section. Finding
Minimum Dots is only a part of the process and is essential for any
graphic designer or Prepress Managers.
 Dot
Philosophy
Challenging
Press
Author: Mariana Tsekos
Graphic Technologist

Why are new types of halftones defined? This

is a question that always arises in the minds of
graphic designers and production managers.
The need for new halftone shapes can create
more special events in the world of printing,
create different quality and help more accurate
production. But which type of them can be
useful for our printing activity? Can we
use any shape for any print activity? In this
section, we want to discuss the issue of rip
and the very important element of halftone in
printing process.

44 PREPRESS | EDITION 05 | JANUARY 2023

New modulation philosophy
is challenging the print shop
as more types of raster are
now available; Stochastic,
Hybrid, Spiral and Concentric
are some of those.
 The Quest
Printing presses can be stable, but not consistent; Solid ink densities will
naturally vary through the press run, and when they do, dot gain and ink
density on the halftone dots varies. Consequently, we face a variation in
tone and color reproduction through the press run.

The tone variation happens, because the large midtone dots in an AM/XM screen
can accept more ink than the smaller ones in the highlights and deep shadows;
though, as solid ink density varies, midtone color goes darker and lighter.

AM is based on a geometric and fixed spacing of dots, vary in size depending

on the tone color represented, usually 10-200 microns. Color curve helps
dots to vary in size.

Conditional dot shapes are Circular, Elliptical, Square, Rugby, and Round
FOGRA; see differences between Round FOGRA and Circular Euclidean dot,
ESKO’s Double Circular and Square dot.

46 PREPRESS | EDITION 05 | JANUARY 2023

 The Proposition
FM (frequency modulation) screen model
have different ink profile; still dots, small
and same size throughout the tone range
(about 25 microns), but distribution
density varies depending on the tone.

The color remains more consistent through

the run; acting much like the highlight dots
of an AM/XM screen, do not take on as
much extra ink as SIDs naturally vary, they
remain more stable.

Furthermore, since FM screening utilizes

very small dots, very fine details are
possible, with significant ink saving.
 How It Works?
In FM screening, the half tone dots are fixed in size.
The dots are arranged randomly according to the tone
value; darker tonal values need more dots = higher
dot frequency in the area, while lighter need less dots
= lower dot frequency.

This is a “pseudo-random” distribution using frequency

modulation to change the density of dots. So one get
a frequency depending structure and not a numerical
distribution. The dots vary in distance, simulating the
technique of Chalcography (Copper Engraving).

Thus, FM screen creates a greater color gamut than the

conventional AM/XM halftone screen frequencies.

The feature is very favorable for printing on rotary

machines where the misregistration is very common
due to effects such as web growth.

Also known as web stretch: a physical distortion

occurs to paper printed on a web press, thus the term
“web growth”. The deformation (stretch) of the paper
when printed on the various color units of a typical
web press happens as the paper absorbs ink and
water causing the paper to stretch. This stretching
and/or shrinking combination becomes accelerated
due to the existence of pressure and tension of
moving paper at a high speed, through the various
cylinders of a web press.

The use of FM screening allowed a UK publisher

named Archant, to switch his production to fonts with
“tiny holes” permitting a reduction in ink, without
turning the fine text to grainy. The result was a
significant reduction in production costs.

48 PREPRESS | EDITION 05 | JANUARY 2023

Good news
for the print shop!
The printer can get LPI Integrity. Rosette can often create moiré, so is very
unstable; The visibility of the rosette can change, then misregistration
is probable, creating a numerous issues, i.e. in sensitive skin colors;
may not be visible when in register, becomes annoyingly visible with a
slight misregistration or misposition. Since FM screens do not produce
rosettes, they maintain their LPI image integrity.

Misregistration alternate overprint and ratios of wet/dry trap; while

dots overlap (even so when are mispositioned / misregistrated), they
normally alternate colors. This can be particularly troublesome in grays,
blues and light colors. Again, since FM screens don’t have a rosette,
color and tone are better preserved. FM screening can help deliver more
presswork color. It succeeds color accuracy and extended color gamut,
giving the industry a strong competitor.

Finally, FM offers Faster Ink Drying helping the presswork dry faster;
tones are built with many-many small dots. Those microdots carry a
thinner ink film and are distributed in a smooth pattern, allowing the ink
to pop off its volatiles.

Faster drying benefits:

Easier to align presswork with proof, closer to digital proof - they are both
dry ones
Reduced set off Less spray powder
Better printing on uncoated substrates, newsprint, foils and plastics
Jobs go faster to bindery Better delivery terms
Heatset presses can lower a few degrees their drying ovens - less power
consumption, less energy costs
 The new philosophy is
challenging the print shop
As far the “Printer’s Devil” exists, even so the through the RIP), then a “softer”, a poor image
“Fake of the Novice” does; it is necessary to can be created. Another question is, when the
understand that if FM screening is only used LPI of the screen (AM-XM-FM) are higher, then
for “special jobs” then press operators never the detail rendering are higher too. Hence, bad
get used to how it performs on press. details and flaws of the original image become
visible and “better” reproduced.
Prepress must cooperate and help the
printer to give its best. Many tests, trials, Presswork color and industry standard
charts, measurements and curve corrections (SWOP, GRACoL7, etc) alignment; the larger
will be required to achieve the best result. color gamut is true, appearing more vibrant
Furthermore, prepress need to understand the colors than the same screen tint build in a
function of each screening, the reason and the lower LPI AM/XM screen (it usually effects
convenient way of processing for each artwork vectors and normally does not show up in
and simulate it to the press. images). So, it is possible to be needed a gamut
reduction with color management / new
Extended process control is needed as the image separating, in order to taint color builds.
dots get smaller. If issues in a 175 LPI print Spot colors are normally not formulated to be
process occur, then high frequency screening halftone screened. Hence the impact of using
will maximize their presence. Those are the a high frequency screen with increased gamut,
most common reasons that cause printers to can lead to an unexpected color appearance.
fail. Thus, all propositions would not concern
specific tasks but the whole production. Piling; may occur on heatset web presses and
is usually caused by not following protocols for
proper blanket wash-up or poor ink rheology.
Keep aware of these: Using inks formulated for large dots of AM/XM
screen, rather are formulated for smaller FM
Grainy tint areas; usually doesn’t occur with dots, too. Thus, an ink that operates with a 200
AM/XM screening. The inconsistent plate LPI AM/XM screen will equally do with a 20-
imaging is a common possible cause, or the 25 micron FM screen (piling is rare on sheetfed
plate doesn’t have sufficient resolution for the presses).
required dot size. Graininess can also occur
when screening back a spot color (spot colors Mottle; is usually the result of poor ink
are normally not formulated to be halftone). transfer, wrong ink composition, fountain
solution condition, paper surface and coating.
Poor image; do not resample high res images. It can also occur on back screening of a spot
The problem happens when high dpi images color. Thus their pigment grind may be too
are resampled to a lower res; when the PDF coarse for the dot size being used.
is created (or resampled or the image goes

50 PREPRESS | EDITION 05 | JANUARY 2023

Individual results
and benefits
1. STOCHASTIC
From the Greek “stokhos” which in mathematical
terminology refers to a random probability distribution.

Due to the random distribution of microdots on the

surface, the composition with more colors is possible,
without the risk of moiré and without the phenomenon
of overlapping dots and misregistration during printing.
Color transition is smooth and offer excellent sharpness
in images, especially in very small elements, lines and
edges are straight and no grainy. Skin tones and true-
to-life color are better reproduced. Color stability is
possible. SIDs and dot gain naturally vary during press
run. A 10-15% of ink reduction is achieved with an FM
screening (depending on tone content).
 Summarizing them:
Does not create rosette patterns
No screen angle moiré, thus no moiré at the artwork
4+ color printing is possible
Photo-like reproduction - Fine details (halftone dot sizes can be as fine as
10 microns, offering a quality comparable to that of photographic prints)
Greater tone (even on misregistration)
Color stability (even on misregistration)
Halftone dot structure stability on misregistration
Larger color gamut
Faster drying
Reduced ink usage
Cost effective

As per disadvantages we could name:

Special care and cleanliness required in press, because of the small dots
used (especially when plates are film depended)
Amplifies dot gain - FM microdots on press resist to added ink densities
caused the difficulty of color and tonal adjustments
Printing stability is very important; lot of dot gain occurs
Long run length stability is harder, because of the microdots (new FM
screen generations are improved)
Hard transfer from film to plate during the plate making process (before
CtP technology)
Harder midtone control and depended of dots cluster; noise or mottle
can occur, when dots connect or overlap.

2. HYBRID
From the Greek word “hyvridio” which means the creation by 2 different
species.

Due to the random distribution of microdots on the surface, the composition

with more colors is possible, without the risk of moiré and without the
phenomenon of overlapping dots and misregistration during printing. Color
transition is smooth and offer excellent sharpness in images, especially in
very small elements, lines and edges are straight and no grainy. Skin tones
and true-to-life color are better reproduced. Color stability is possible. SIDs
and dot gain naturally vary during press run. A 10-15% of ink reduction is
achieved with an FM screening (depending on tone content).

52 PREPRESS | EDITION 05 | JANUARY 2023

Hybrid is a combination of the FM and LPI (on selected systems) and a complete
AM screening. Thus, different type, larger tone range 1 – 99% on paper.
and smaller dots are used to cover the
area, permitting better printing stability, Thus, one can select the right minimum
improved press run length, smoother flat dot for highlights and shadows and
tints and higher contone (continuous range balance selection to get the maximum
of tones from white to black) density. quality for the expected run length. Hybrid
is dedicated per plate type and CTP. These
The dots that are used in the majority small dots are supported in the highlights
of the job’s tonal values areas are by non-printable microdots that result in
generated using the conventional AM higher stability during run length. Also,
screens, while the highlights (maybe one can grow the dot size and the random
the deep shadow areas also) use FM placement, achieving a better connection
screening. This allows highlight areas to and printing stability on large gaps. Finally,
be printed without too small dots to be the dot gain is more under control. It is also
held on press. possible to specify the size in pixels of the
FM dots to be used in the highlight and the
While in midtones uses AM screening and shadow areas of the job.
in highlights / shadows uses FM screening,
is possible for the press to get 240 LPI The reader will experience the difference,
without extra efforts, adding 280 LPI - 340 not the printer!
 How It Works?
AM halftone dot shrinks, from the midtone tints, till smallest
reproducible dot is reached. Then highlight / shadow tints are
obtained by handling these smallest printable dots in FM; no
more random dot placement.
No stochastic but still AM; highlight and shadow details just
look stochastic. Rather, they are FM implementations of dots
placed at the continuation of traditional angles defined in
midtones.
AM to FM transition point is line frequency depended.

The advantages namely are:

Better Printing stability
Dot gain more under control because dots close better
More clustered dots in the highlights to midtones, more
robust than standalone small dots
Non printable little dots supporting neighbor printable dots
Enhanced print quality with a better detail reproduction
Improved registration accuracy
Excellent color reproduction
Run length improved
Reduced ink consumption up to 15%

54 PREPRESS | EDITION 05 | JANUARY 2023

Below, hybrid printing, adding spot color with transparency on CMYK image; with ADOBE
all colors under spot are converted to FM while in ESKO, the image keeps AM and the spot is
converted to FM, giving a better result.

Benefits for FLEXO

Hybrid is very popular with flexo printers as it allows recovering
highlight and shadowing tones that would otherwise be lost.
The most popular benefits are:
Vibrant colors
Better printing stability
No breakout of small dots
Smoother tints
Surprisingly high line ruling - Up to 170 LPI on corrugated - Up to
212 LPI on plastics
Anilox with lower cell count [1/6 ratio over ruled: 212 LPI on
900 anilox (> 150) - 175 LPI on 600 anilox (> 100)]
 3. SPIRAL
From the Greek word “spira”, the winding shape that combines
symmetry with golden ratio.

In the prism of symmetry and the golden ratio, spira reflected

for the ancients the sense of harmony and beauty.

The definition of the spira was made by Archimedes around

220 B.C. where it is specified that the width between two
successive windings remains constant. Spira was used as a
decorative motif; Illustrations have existed in Greece since
prehistoric times (around 1200 B.C).

Is a new dot shape, looking like spire. The innovation belongs

to AGFA and is included in the AM screening range. It uses
degrees and a rosette like the conventional AM raster. Those
dots are replaced by the spiral dot which is “custom” in
relation to the thickness of the line depending on the print,
allowing the reduction of ink uptake.

Due to the shape of the dot and because of the white

areas inside it, this new technology achieves an average ink
reduction of 10%.

The concept and aim are to make prepress and printing

operations cleaner, more cost-effective and easier to
manage and maintain; Spiral lets you hold a 1-99% dot,
vibrant colors, reducing image slur and does not require
expensive upgrades for CTP or press.

56 PREPRESS | EDITION 05 | JANUARY 2023

The benefits of Spiral are:
Very large reduction of moiré in printing
Improved color reproduction, especially in blue shades
Clearer images, especially in dark tones
Less transparency, allowing the use of thinner paper
Cost effective

To avoid moiré, try to change the Y ruling in Advanced Screen Setting and lift it by 15%. Keep
in mind that you have to use the Clear Center Rosette pattern (an ESKO AE option).

4. CONCENTRIC
The word comes out of the Greek “kentro” (in
latin “centrum”) and refers to the point from
which all points on the circumference of a circle
or the surface of a sphere are equidistant.

ESKO is featuring the Concentric dot,

where the solid AM dot is divided into thin
concentric rings. 1-2 pixel width Concentric dots could be
problematic for imaging systems.
Concentric screening doesn’t offer additional
gamut - possibly less - comparing with AM/ In conclusion, the use of the above mentioned
XM screens at the same LPI, because of the screenings requires a prudent choice and
difference in ink coverage area. As an AM screen knowledge of strong points and weaknesses
there is still the chance for screening and moiré, of each.
although it seems being less problematic,
because of its finer shape. Technology goes on, giving us great results and
many options, but the best choice is up to us to
The thinner ink films and the need for tone be found. You can be part of the development
reproduction curves for plate imaging leads to and help your company to be leader in the field.
ink reduction. Source: Agfa – Esko – The Print Guide
 Questions
& Answers

58 PREPRESS | EDITION 05 | JANUARY 2023

This is where we connect with you
by Prepress Magazine Team

How to prevent different costs in printing?

It is necessary to know that most of the costs happen during printing, but the
main reason can be examined and solved in Prepress.

For example, when you use a lot of color in the background level of the design,
the software draws it but does not give you any information about the printing
cost. A large amount of ink on the surface of the printed material can create
unevenness and prevent quick drying. In this condition product manager reduces
cylinders’ pressure.

In this case, either the final color loses the necessary saturation or the print quality
damages. To reach the correct ink density, a lot of time must be spent which
is a kind of cost. In another example, the amount of Dot Gain can be defined
according to the Color Profile setting at design time.

You can set the approximate Dot Gain amount and paper type on a small file
with detailed content and apply it to the digital file to avoid quality loss. As you
see, many costs including time, energy, manpower and financial issues can be
examined and solved at Prepress time by suitable knowledge.

The packaging structure is one of the issues of product production. Should the
graphic designer also have information about structure modification?
When an idea comes to the stage of design and then printing, all people are
somehow involved in this process. Printing means performing a team activity.
Although each team member rarely meets each other or they are not in a
company in the real sense but they must cooperate in the production path.
 Graphic designers are responsible for conceptualizing and implementing graphic
design, but the first step in structure designing is taken by them. Designers must
either coordinate with the production manager or be aware of the principles of
printing themselves. The point here is that many designers limit themselves to
only creative subjects.

Packaging is a product that all factors including graphic designer, print supervisor,
production manager, structure designer must be aware of each other’s activities.
Sometimes some of these activities are done by one person, but in any case,
cooperation leads to the correct production of a product.

What are the basic rules for product production in packaging design?
Many items can be mentioned but one of the first items in packaging design is
paying attention to the dimensions of the product and the type of Carton Base.
Companies such as FEFCO & ECMA In terms of dimensions, the type of folding,
the amount of cutting and the layers of cardboard, have a compiled standard. All
these items can be included in a Handbook.

Another item is ISO12647 standards using. The ISO organization has defined
rules about color amount, file storage type and production structures. In addition
to the mentioned items, attention to the structure of Color Profiles expressed by
Fogra can also help to correct production.

Remember that each printing house or advertising company doesn’t comply with
these conditions, because both execution time and high knowledge are needed
to define these standards from design to printing.

What are the ways to print color with the least difference
compared to the monitor?
Color printing subject has many points. These points can be examined during
Prepress or Press by print supervisor or Q.C. Manager. But a few points are very
important in color setting. At first it should be remembered that even at the best
calibration mood the monitor cannot show you the correct and accurate color. So
even in the most ideal conditions never fully trust the monitor.

The monitor is only responsible for displaying the color according to the initial
settings. However, it cannot simulate the ink density, the pressure of the cylinders,
the effect of humidity and temperature on the color.

The second point is that one person in your team should always be responsible
for color control during printing. This person can be yourself or someone on the
quality control team.

In these steps, remember that the colors density is higher than what you see on

60 PREPRESS | EDITION 05 | JANUARY 2023

the monitor. For example, setting the black color code on a monitor above 60%
can simulate a decent dark color but this darkness is due to the combination of
different levels of RGB on the computer and is only a preliminary simulation.

This color becomes darker when printing with high ink, cylinder and plate
pressure, and a change occurs. It is suggested to always prioritize the use of
standard coloring books..

What are the ways to create special colors such as gold and silver?
Some inks have a special formulation at the production time. For example,
metallic, golden, silver colors are included in this category. The brightness of
these colors is caused by pigments and additives in the ink. There are also certain
companies that produce these types of inks with precise formulations and you
will see satisfactory results at the printing time. The cost of production in this case
is very high.

So first check if the employer really needs to use these types of inks or not! The
next point is to use CMYK mode for the equivalent codes of each of these inks.
That means you either produce using Pantone and Spot Colors or you simulate
the equivalent of the same inks using the numbers in CMYK. In the second case,
the main colors of the print cannot create the luster and metallicity of the ink but
because of the similarity, they create a good result. The cost of production during
the simulation of inks is low but you should talk to the employer about this type
of inks application and get the final approval.

The material in Flexography printing is transparent. How to prevent color

change during printing?
Remember that the if product inside the package, is a colored liquid, can affect
the designed color of the label. for example, yellow oils can compensate part
of your design needs for color and this is smart thinking. There are some labels
that are designed only in white but the liquid color inside them can help the
readability of this writing.

At the printing time by a flexo machine, most materials are transparent and if
you want images and graphic elements to be seen easily without using color
inside the package you must use a white mask. This means that you define a
white color layer in the lowest layer of the design so that at the time of printing,
white is printed first and all other colors are placed on it. In this case, the color
of the bottle or the liquids inside it have very little effect on the designed colors.
The white mask layer is usually defined as Spot and to coordinate with most
manufacturers, this mask is created as Magenta=15%.
 Choices and Actions

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