Final Development
With three different designs to choose from, it was at this point that “scope creep” or expansion of the range of the project began to happen. The original plan was to choose a design and reproduce it in 4-color process. Since there were different designs to choose from, the next consideration was to print one design in four process colors with combination spot colors and another design using 7-color expanded gamut (EG). Everyone on the team became intrigued with the idea of presenting a sample that reflected FIRST with both printing methods. This would show that the FIRST methodology can be easily applied to both processes without having to change any of the aims or controls set during the optimization step.
An interesting aspect during the development of the final package design and production plan was that the project became more complex in its execution; however, there wasn’t a great concern to anyone on the team whether we could execute the project and meet all of the various expectations. I believe much of this goes back to trusting and following the process.
After much deliberation, it was decided that all three designs would be used. The project would print a total of 10 colors with two lanes of plates across a single web, with one set of the three designs printing in 4-color process plus two spot colors and the other set printing in 7-color EG.
This project would require strict compliance within all of the workflows, such as the preparation of the art files and application of the curve and profile, as well as the proper “tagging” or identification of the printing plates by The ALC Group. It would require PPT assign specific instructions to the mounting team to eliminate potential registration issues and that the press operators maintain the process controls necessary to match the aim targets to provide accurate color reproduction—all in keeping with FIRST.
The end result would present three designs printing simultaneously in two different separation methods, creating 21 colors (plus white) using 10 ink stations, all in one single pass. All hard-copy proofs would be evaluated against the printed sample after the aim targets had been matched at press, leaving the operators to truly “run to the numbers.”
[perfectpullquote align=”full” cite=”” link=”” color=”#545453″ class=”” size=””]”We felt it was important to utilize all of the standards that have been discussed at previous FTA events and in FLEXO Magazine articles, and that are being successfully implemented within the packaging industry.”[/perfectpullquote]
Achievable Results
The new objective for the “FIRST in Motion” session became: “To demonstrate the FIRST methodology in a flexographic wide web environment producing three different designs in 7-color EG in one lane while printing the same three designs in traditional 4-color process with two spot in the other lane—all in one pass.”
This project became very complex in its scope and expectations, and provided a real-world example of FIRST in motion. Every step provided key learnings including an opportunity for future process improvement of CMYK spectral color aim targets.
The “FIRST in Motion” project would prove predictable results are achievable when standards are set and process control is maintained within each step of prepress and print production.
About the Author: Bob Coomes joined Plastic Packaging Technologies LLC in 2007 to develop the position of graphic and premedia leader. This position was created to serve in the communication and coordination of various designers, marketing teams and prepress companies involved in the production of printed flexible packaging.
With his current role as graphics, prepress and print specialist, Bob leads/supports the workflow and processes from package design through print production on all projects at PPT’s facilities in Kansas and Ohio. This includes package design and development for the industrial, food and retail markets, maintaining of process control standards for brand/color management, optimized methods for prepress (proof, plate and ink technologies) and continued improvements in productivity and print quality in the pressroom.
Bob was the co-chair of Forum 2017 and chair of Forum 2018, and has spoken in and chaired sessions at FTA events. He has earned his FIRST Implementation Specialist Certification and FIRST Prepress Operator Certification. He continues to serve in various capacities for FTA, PLMA and the GCEA.
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