How to Automate Offset Press Process Control with a Closed-Loop Solution
For printers with an older offset press, it can be difficult to deliver the same color results as printers with a new press with automated color controls. Adding a closed-loop solution offers affordable automation so commercial print shops and folding carton converters can continue to compete in today's market.
Challenges
Print work is driven by specifications that require manual spot checks and ink key adjustments throughout production. Many printers struggle to quickly hit offset lithographic color targets on a sheet-fed press.
- Getting up to color can waste over 600-800 sheets of paper and ink per job.
- Innovative inks and substrates make it challenging to maintain color accuracy throughout a print run.
- As customers strive to harmonize multiple pieces, they are tightening tolerances and increasing no charge returns.
- Shrinking margins demand greater manufacturing efficiency and shorter make ready times to produce accurate color.
Solution
A closed-loop solution that includes an X-Rite scanning system and software, including MeasureColor and Rutherford, is an affordable way to maximize performance and extend the value of an older press by monitoring color and alerting operators to any deviation. The solution can be customized based on press size – the eXact Auto-Scan is ideal for print shops running 29”/74cm or 40”/102cm sheet-fed presses, while the IntelliTrax2 offers highly automated, non-contact scanning of 2mm color bars for 40”/102cm or larger presses to capture process colors, spot colors, PANTONE® colors, paper color, tone value increase, gray balance, and ink density in less than 10 seconds.
As color data is captured, if any drift is detected, Rutherford software immediately prompts the operator with ink key adjustment recommendations to bring color back into tolerance with minimal intervention. Together, these tools support a fully standards aligned workflow, enabling printers to meet client specifications and print to most global graphic arts standards, including M1 for optical brighteners and full support for G7, GRACoL, SWOP 2013, PSO, and FOGRA 51 and 52.
Results
A closed-loop solution pays for itself within the first year by reducing make-ready, ink, paper, and labor waste, and allowing for additional jobs each day. Try our ROI calculator to see how much you can save.
The eXact Auto-Scan is a game changer in our print shop. Our press operator can put the sheet on the eXact Auto-Scan console and hit measure – no lining up, no fiddling or moving the head back and forth to get the laser on. This saves us time and helps us reduce any errors. The eXact Auto-Scan is a must-have device for any print shop with a multi-color press.
~ Rick Fougere, General Manager, J&R Graphics
How it Works
Prepress Setup: Prepress provides a .cip or .tiff file containing all the data Rutherford software needs to automatically preset the ink keys. The press operator simply selects the print job and paper type on the touch-screen monitor, and the software creates a reliable starting point.- Automated Scanning & Rapid Feedback: The eXact Auto-Scan or IntelliTrax2 scanning system automatically aligns to capture a color, sending color data to the Rutherford software for real-time, on-screen access within 15 seconds.
- Real Time Color Correction: If color starts to drift, Rutherford software alerts the press operator and offers ink zone recommendations, which the operator can initiate or reject with one touch.
- Continuous Monitoring: Throughout the run, operators can periodically rescan sheets to verify that color remains stable and within tolerance, ensuring consistent output from start to finish.
- Standards Alignment & Ink Room Integration: Through MeasureColor, both scanning systems can access the PantoneLIVE database for accurate spectral target values for corporate and other spot colors. They can also extend to the ink room for an end-to-end standards-compliant workflow, integrate with NetProfiler to ensure instrument consistency, and exchange job data with ColorCert for statistical process control.
Featured Products
Ideal for high-end, high-speed printing/converting operations, IntelliTrax2 offers highly automated, non-contact scanning of 2mm color bars for 40”/102cm or larger presses to capture process colors, spot colors, PANTONE® colors, paper color, tone value increase, gray balance, and ink density in less than 10 seconds.
Ideal for print shops running 29”/74cm or 40”/102cm sheet-fed presses, eXact Auto-Scan is a versatile press side scanning device provides flexibility for measuring color with spot, manual, and automated scanning capabilities.
Provides real-time color feedback, helping press operators achieve consistent color faster while reducing make-ready time and improving efficiency. By minimizing guesswork, it streamlines color control throughout the print process.
Decrease Make Ready and Improve Profitability
A closed-loop solution addresses a lot of pain points and frustrations in small to mid-size commercial and folding carton print shops through faster make ready, less waste, and process standardization for consistent and accurate color and a more sustainable process.
