MULTIPLE UPS PRINTING IN CONTINUOUS STATIONERY:

REASONS FOR PRINTING IN MULTIPLE UPS:

1.It reduces production time.

2.Increases the efficiency of the process.

3.It reduces printing, binding and other post press works.

4.Reduces time for inspection, sorting and setting.

5.Maximises the utilization of man power, paper and machineries.

6.Reduces the number of image carriers.

7.Reduces the number of make ready.

FACTORS AFFECTING MULTIPLE UPS:

1.Paper availability.

2.Max. feeding size.

3.max. image size.

4.Number of numbering machines, perforation blades that can be mounted at a

time.

5.item size of the product

6.Quality of the paper- bulk, creasing effects etc.

CONDITIONS FOR GROUPING DIFFERENT

ITEMS/COUPONS/CHEQUES/STATIONERIES:

1. Items should have same coloured back ground in case of cut color/ pantone
shaded jobs.

Because in cut colored jobs it is difficult to crate different colors, but different
designs in same color or different text images in same color can be grouped.

e.g. Rs 200/- coupons with Rs 50/- and Rs 100/- of same background color.

Or cheques of different regions /branches with same back ground color like
Savings cheque with branch name manipal, mangalore ,bangalore and so on.
2. If job is four colour or CMYK pattern then irrespective of the background color,
design we can group different coupons in one plate.

3. Quantity of all items grouped in one plate should be same. To avoid waste
production.

4. Item size of all coupons must be same , to utilize the paper effectively.

5. Paper /substrate must be same for all grouped items.

6. Numbering pattern and design, embossing, hologram etc such features

should be identical for online process.
 DEPARTMENT OF PRINTING AND MEDIA ENGINEERING

ASSIGNMENT-01

SUBJECT: CONTINUOUS STATIONERY AND SECURITY PRINTING

SEMESTER: SIXTH

Q NO. 1. Prepare an Integrated card for an hospital patient record purpose with
following

requirements and specifications in continuous stationery format-3 forms

Size of the form= A4, size of the Integrated card= 2”x 3.5”

Position of the card=top left (1cm left from the right edge of the form &
1cm from the top edge)

Paper= 120 gsm map litho, with die cutting, backside with patch material.

Numbering= 6 digit red numbering.

Show the sprocket holes position, vertical perforation to tear away the
punches

Provide horizontal perforation 4’’ from the top edge of the form.

Q NO . 2. Prepare an Integrated card for an hospital patient record purpose

with following

Requirements and specifications in continuous stationery format-3 forms

Size of the form= A4, size of the Integrated card= 2”x 3.5”

Position of the card= right bottom (1cm left from the right edge of the
form & 1cm from

the bottom ),Paper= 120 gsm map litho, with die cutting, backside with
patch material.

Numbering= 6 digit black numbering both on card and form.

Show the sprocket holes position, vertical perforation to tear away the
punches
 Provide horizontal perforation 4’’ from the bottom edge of the form.

Q NO .3 . Prepare an Affixed card for an hospital patient record purpose with

RFID and with

the following requirements and specifications in continuous stationery

format-3 forms

Size of the form= A4, size of the Affixed card= 2”x 3.5”.

Position of the card= right bottom (1cm left from the right edge of the form
& 1cm from the bottom ),

Paper= 120 gsm map litho, with die cutting, backside with RFID.

Numbering= 6 digit black numbering both on card and form.

Show the sprocket holes position, vertical perforation to tear away the
punches

Provide horizontal perforation 4’’ from the bottom edge of the form.

Q NO . 4 . Prepare an Affixed card for an hospital patient record purpose with

RFID and

with the following requirements and specifications in continuous

stationery format-3

forms . Size of the form= A4, size of the Affixed card= 2”x 3.5”. Position of
the card= right bottom (1cm left from the right edge of the form & 1cm
from the bottom),

Paper= 120 gsm map litho, with die cutting, backside with RFID.

Numbering= 6 digit black numbering both on card and form.

Show the sprocket holes position, vertical perforation to tear away the
punches

Provide horizontal perforation 4’’ from the top edge of the form.

Q NO.5. Prepare an Integrated label for an transport record purpose with

following

requirements and specifications in continuous stationery format-3 forms

 Size of the form= A4, size of the Integrated card= 2”x 3.5”

Position of the card=top left (1cm left from the right edge of the form &
1cm from the top edge) Paper= 120 gsm map litho, with die cutting,
backside with patch material.

Numbering= 6 digit red numbering.

Show the sprocket holes position, vertical perforation to tear away the
punches

Provide horizontal perforation 4’’ from the top edge of the form, provide
prismatic or

rainbow color printing.

Q NO . 6. a) Prepare a commercial diagonal seam envelope with window cutting ,

Bar code

printing, Size of the envelope=8”x11”,Gsm=80 gsm map litho with

peel and seal adhesive type.

b)Prepare an expansion envelope ,size=5”x9” with gusset edge of 2”(on

opening)

Paper= 120 gsm card /maplitho with peal and seal closure method.

Q NO.7.Prepare a 3 ups , 3 part continuous mailer with item size= 3”x9”(after

peeling) and

provide stub of size 1cm on the both sides with carbon insertion in
between the forms. Provide 1:2 perforation on stub, add sprocket holes
to this,

Paper= 80 gsm map litho- 1st part, 58 gsm for 2nd and 3rd parts.

Use 6 digit black convex numbering .Use peel apart technique to open and
fasten the

forms by means of crimps and glue.

Q.NO.8.Prepare a 3 ups 3 part carbonless mailer with peel apart technique to

open it.

Item size= 3”x9”(after peel off),stub=1cm, show sprocket holes with prper
margin,

Paper= 80 gsm for 1st part, 70 gsm for 2nd and 3rd parts, Use 6 digit black
convex
 numbering.Use peel apart technique to open and fasten the forms by
means of crimps and glue.

Q.NO.9.Prepare a 3ups 3part hot spot carbon mailer of item size=3”x9”

On the front provide delivery address and this address is to be printed on

the remaining forms . Use 6 digit black convex numbering. Use peel apart
technique to open and fasten the forms by means of crimps and glue also
show the position and margin for the sprocket holes.In addition to this
provide block out to hide the secured information printed in the second
part by Hot spot carbon.

Q NO. 10.Prepare a 2 part mailer with insert, item size -3”x9”, insert size
+2.5”x8.75”, fasten

the forms by means of crimps and glue . Provide thumb notch to remove
the insert and also display the instructions to open the insert .Use any
correct method to transfer the image on to the insert .Paper= 80 gsm map
litho for the mailer, 90 gsm for the insert.

Q NO .11 .Prepare a 3 part mailer with fly sheet and hot spot carbon to transfer
the image to

2nd and 3rd part. Provide stub & peel apart technique , also show the
instructions to

peel apart in 3ups, fasten the Forms by means of crimps and glue,

Q NO .12 . Prepare a 2 part pin mailer in 3ups with Block out , to secure a pin
number and

with spot carbon to transfer the pin number also show the delivery
address on it.

Also provide sprocket holes , peel apart. Item size is 3”x 9”. Paper=80
gsm for the

both parts. Fasten the forms by means of crimps and glue,

Q NO . 13. Prepare a 3 part mailer with combination of carbonless paper , Hot

spot carbon and
 Peel apart technique. Show the sprocket holes, stub portions with
perforations .

Item size: 3”x 9”, Paper =80 gsm map litho for all 3 parts, fasten the
forms by means

of crimps and glue,

Q NO.14.Prepare a 2 part mailer of size 3”x9”with reply insert of size

2”x8.5”.Provide Tab

opening on the top with sprocket hole, perforation and also write the
instructions to

open the mailer in 3 ups . Paper gsm= 80 gsm for 1st part, 60 gsm for 2nd
and 3rd

parts. Fasten the forms by means of crimps and glue,

Q NO.15. Prepare a 3 part mailer of item size 3”x9” with slit on back side to insert
the business

reply card of size 2”x8”, printed with senders address. Provide

advertisement in 3rd part, and hot spot carbon in between 1st and 2nd part to
transfer the image. Add block out to secure the pin number printed in the
2nd part. fasten the forms by means of crimps and glue, Paper for 1st part-
80 gsm and 60 gsm for 2nd and 3rd parts. Show the sprocket holes ,stub
portion and vertical and horizontal perforation s to separate the individual
mailers.

Q NO.16 . Prepare a envelope of size 4”x 9”with Tuck in flaps for closing and with
a window

of size 1.5”x 2.5” to view the contents .inside the envelope insert
promotional materials and business reply envelope with two way
mailer type (size 3”x6”)and the business reply should have peel and seal
provision to close and with senders address, postage considerations.

NOTE: Last date for the submissions of the assignment is- 30/03/2009
 ASSIGNMENT -02

SUBJECT: CONTINUOUS STATIONERY AND SECURITY PRINTING

SEMESTER: SIXTH LAST SUBMISSION DATE: 06/04/2009

Q.NO 1 . Prepare a planner for numbering cheques, to be printed in 12 ups.

Ordered quantity= 1000000 leaves.

Lvs books sl. no from to

50lvs 10000 000001 500000

25lvs 5000 500001 625000

10lvs 4000 625001 665000

20lvs 16750 665001 1000000

Q.no 2 . A firm received an order for printing 20 lakh 3 color cheques in 95 gsm MICR grade
paper. The Item size is 8.5” x 3.67”.the printer has 2 options to print this order he can go for
sheet fed or web offset printing .The requirements and capacity for each m/c is given below.

Sheet fed-2 color:

Paper size available : 49cms x 67 cms.

Feeding size : 49cms x69 cms

Printing speed : 10000 impressions/ hr

Machine cost : Rs.500/hr

Ink milege : 15000 impressions/ kgs.

Ink cost : Rs.450/kg.

Total prepress cost : Rs 10000/- net

Paper cost : Rs.58/kg.

% age wastage :4%

Web offset:3 color m/c

Printing speed : 15000 impressions/ hr

Paper size : 43 cms web

 Printing unit size available :22” and 24”

Machine cost :Rs.1000/hr

Ink milege :15000 impressions /kg

Ink cost :Rs 400/kgs

Total prepress cost :Rs 12000/- net.

Paper cost :Rs.52/kg.

Post press cost :Rs.100/ 1000lvs.

% wastage 6%

Considering all these factors decide the machine on which you can print the job more
efficiently.

Q No.3.There is an order for printing 30 lakh cheque leaves ,books of 50 leaves .for
which numbering is 200001 to 32,00,000.

The customer wants 25000 lvs immediately, as entire lot printing and binding takes
more time , Printer plans to print 25000 lvs first and then he takes the printing of
remaining quantity. Prepare a planner for printing this order in 12 ups and also in
15ups.

Q.NO.4.A printer dealing with printing of continuous mailers , has received an order to
print 20 lakh 3 part carbonless mailers of item size

7” x 3”( size excluding punches).later these mailers undergo bursting and trimming
to convert into unit set of size 7” x 3”,either on

line or offline based on the machine selected below.

The printer has two options to print this order, He has a 4 roll multi web & online
converting m/c , whose output is in unit set form &

Another , single web m/c ,where printing ,punching, perforation is done online and
collating of all forms and conversion to unit set is done in a roll to unit set collator.

The various cost heads for each option is given below. Paper available is 18” wide
web in all CB,CFB and CF varieties.

Paper cost is for CB- Rs.80/kgs, CFB-Rs.100/kg, CF-Rs.85/kgs.

MULTIWEB(with converter)

Machine cost :Rs.2000/hr.

Printing speed:15000mailers/hr.
 Feeding size :10”

Printing unit size 22” and 24”

Ink milege :15000/kg.

Prepress cost :Rs.4000/-

SINGLE WEB-OFFSET:

Machine cost- Rs.750 /hr

Printing speed30000 mailer /hr.

Feeding size :20”

Ink cost : Rs.250/-kg

Ink milege 15000 impression /hr.

Prepress cost :Rs.4000/- net

COLLATING MACHINE (ROLL TO PACK)

Collating speed :10000 mailers/hr.

Collating m/c cost :Rs.250 /hr

Collating materials expences :Rs.0.20 per mailer.

Decide the best combination machine for printing this job cost effectively.

Q.NO.5 Recently a printer has received a order for printing 20 lakh commercial envelopes of
size 8” X 4”,in a 90 gsm maplitho paper. He has option to print in sheet fed and in
web machine & subsequently the printed sheets are given for a letterpress die
cutting m/c. The various requirements and conditions of the machine are given below
.Select any one combination sheet fed l/p or Web offset and L/p , in order to print
cost effectively.

Web offset:

Paper available : 20” web

Printing units available: 22” & 24”

Printing speed:15000 impressions /hr in 22” /24”

Machine cost :Rs.1000/hr

Ink milege :10000 impressions / Kgs. In 22”/24”.

Ink cost : Rs.320/Kg.

 Paper cost :Rs 48/kg.

SHEET FED OFFSET m/c:

Paper available :50cms x 60 cms

Paper cost :Rs.50/kg.

Printing speed :8000 impressions /hr

Machine cost :Rs.500/hr

Paper feeding size :30 cms x 50 cms

Ink milege :10000 impressions / kgs.

Gripper margin :1cms

DIE CUTTING M/C L/P

Max. feeding size :30cms x 50 cms

Gripper margin :1”

Impressions :5000 /hr in 30 cms x 50 cms

Machine cost :Rs.200/ hr

Manual gluing and finishing cost:Rs.0.30 /envelope.

Q.No. 6. There is an order for printing 2 lakh 4 color statements of size. 15”x 8”.Printing is
planned to a single web 4 color offset machine with blanket joint of 7mm( where
image cannot be produced).

Printing units available are 22” & 24”

Paper available size-= :15” , 90 gsm.

Printing machine cost :Rs.1000/ hr

Printing speed : 15000 impressions / hr in 22” and 24”

Ink milege : 15000 impressions/ kgs in 22” and 24”

Ink cost Rs 400/ kgs.

Net prepress cost Rs 2000/-

Post press cost Rs 100/1000 statements

Same job can also be planned in a sheetfed m/c for which considerations are,
Paper size available 25”x31”-90 gsm

Paper cost Rs 50/kg

m/c cost Rs 600/kgs

printing speed 10000impressions/hr

ink milege 10000 impressions/kg

ink cost Rs500/kgs.

Post press cost Rs 100/1000 statements

Prepress cost Rs 1750. net.

From the data available above draw a conclusion about the unit cost for the
statement & suggest the m/c where we can print this order economically.