INCQC 2012 Tutorial Verona en 111201

23.11.
2011
INCQC 20122014
Verona, 1. December 2011
Roland Thees, Industrial Engineer Project Manager Consulting WAN-IFRA GmbH & Co. KG ISO Committee Member roland.thees@wan-ifra.org
2011 WAN-IFRA Roland Thees
INCQC 2012-2014
International Newspaper Color Quality Club Organized by IFRA since 1994 Confirms a newspapers high standard of printing quality Helps the newspaper to convince advertisers and agencies of its productivity Supports all efforts of a newspaper to generate customer loyalty by ensuring satisfied and convinced readers
2011 WAN-IFRA Roland Thees, Page 2
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Topics of the INCQC Tutorial

Objective of the competition Benefits of participation and Club membership Time schedule and deadline overview Printing in accordance with the ISO 12647-3 newspaper standard Innovations in the standard expected for 2012 INCQC 2012-2014 requirements, instructions and categories Continuous quality control Self-Check, IFRA Check Criteria and judging the general printing quality Tools and ways to achieve high-quality newspaper printing
Agenda 1. December 2011

Introduction of Trainer and of Participants Importance, use and objective of the INCQC Goals and benefits of standardization Specifications of the Coldset 12647-3 standard Modifications to be expected in the standard in 2012 INCQC procedure, time, schedule and administration
Instructions, technical details and General Print Quality evaluation Quality Management
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Worldwide support
(as of November 2011)
Associazione Stampatori Italiana Giornali (ediland.it) Asociacin Tcnica de Diarios Latinoamericanos (atdl.org) BasICColor (BasICColor.de) EAE (eae.com) Goss International (gossinternational.com)
manroland AG (manroland.com)
Newspaper Association of America (naa.org) Q.I. Press Controls BV (www.qipc.com) Sanomalehtien Litto (sanomalehdet.fi) X-Rite (xrite.com) Zeitungs Marketing Gesellschaft (zmg.de)
Objective of the INCQC

To support the newspaper in relation to customer loyalty (only a satisfied generates satisfied advertisers) To ensure consistently high-quality daily newspaper production To drive the trend towards full-color, attractive newspaper pages To provide marketing materials so that the newspaper can present itself convincingly to agencies as a competent advertising partner To promote the ISO quality standards worldwide in order to ensure a uniform appearance of printed color ads To offer attractive IFRA Club membership in order to promote the sharing of experience
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Benefits of INCQC participation

Ensures competitiveness towards rival media Provides promotional material to help attract advertisers Winners are highly respected and honoured with a prestigious award Workflow is optimized and know-how and competence is gained for the selection of materials and production methods Better control of progress in standardisation based on known parameters Provides a basis for discussions and facts for negotiations with suppliers Motivates personnel and honours efforts Customer complaints can be recognised or rejected objectively based on technical measurements (printing within or outside of ISO)
Reasons for INCQC participation

Result of a survey in January 2011, INCQC + Certification
180 160 140 120 100 80 60 40 20 0
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Registration
Online registration, brochure and instructions under: www.colorqualityclub.org Registration Continuous quality check: www.colorqualityclub.org Run Self Check
Time frame
Instructions available for downloading from 29.06.2011 Registrations received up to 17.10.2011 are offered a free test run in November 2011. The report shows how much optimization work remains to be done. Mailing of a measured reference print in October 2011 Registration deadline for participation is 31.12.2011 Test chart production from January to March 2012 = 1 x monthly Submission of test prints by end of the month in each case Production of the monthly evaluation by 15th of the following month The overall evaluation per category, incl. ranking, ready by June 2012 INCQC awards presentation ceremony during IFRA Expo 2012 in Madrid
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INCQC 2012 Time Schedule

Downloads and test runs
Conditions of participation
A participant is always a specific newspaper title at a specific location Every publishing house and every printing operation can register an unlimited number of titles A publishing house can register several locations eith the same title, thus permitting a comparison of locations Participation is treated with strict confidence Club membership and the certificate are issued for a newspaper title produced at a specific printing location on condition that the minimum number of points stated in the instructions were obtained
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Features of INCQC 2012-2014

Test chart production within the framework of the regular newspaper production times, without resource-consuming special shifts Creation of participant categories in order to cover all processes involved in newspaper production Evaluation of the daily quality instead of special production runs Establishment of the capacity of an operation to consistently satisfy a defined quality level Avoidance to a large degree of a subjective jury No limitation on the number of Club members
ISO 12647
Graphic technology standard that defines process control for production of color separation, proof and production print 7 sub divisions
-1: Measurement methods -2: Offset lithography -3: Coldset offset (Newspaper production) -4: Publication gravure printing -5: Screen printing -6: Flexographic printing -7: Proofing
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ISO for the news publishing industry:

Graphic technology standard 12647-3:2005 12647 is a set of standards consisting of several subversions. -3 is newspaper printing, -2 is the general offset standard, -1 describes the measuring processes :2005 means that this version was published in 2005. As the youngest version, it continues to be valid ISO standards are subject to review at 5-year intervals The newspaper printing standard was published for the first time in 1998 17 pages worth reading
Why standardisation?
Different quality of raw materials Materials from many different suppliers Different newsprints in same production run Batch to batch variations Usual problems Wrong shades of ink, darker newsprint shade, set-off and print through affecting the general print quality, fluff accumulation, runnability issues etc Unless raw materials are standardised, production cannot be standardised
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Advantages of applying the standard

An outstanding characteristic of newspapers is their capacity, despite independent production sites, to achieve uniform colour reproduction worldwide by the use of the ISO standard Deviations can be avoided by known quality parameters Irregularities in the used materials are recognisable and can be eliminated Globally operating advertising agencies and companies expect the exact reproduction of the intended colour tone
Aim of a standardized newspaper production

Plannable, predictable results for the graphic designer Consistently high-quality printing in daily production Personnel management: Increasing quality consciousness and acquiring know-how Personnel motivation by concrete targets Saving costs by analysis of weak points Customer loyalty: Promotionally effective certificate gives competitive edge High-quality product appearance flatters the reader Qualtifiable production quality generates advertiser loyalty
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Standards prevent prints in different visual appearance
Advertisers problem with Newspapers
Identical Artwork as PDF File sent to multiple Printers Printed at many different printing sites Any print locations with specific settings Lots of different Hardware (e.g. presses) and software Different configurations within the presses Country-specific materials like ink and paper => Same Ad may reproduce differently with unstandardised production process
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Core topics of the ISO 12647-3 standard

Tone value increase curve uniformly defined with 26% in the mid-tone Tone value increase within 5% tolerance (+/-) of the tone value increase curve Mid-tone spread between max. 6% 40er chain-dot screen 240% coverage
Newsshade for ISO standard paper
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ISO color values and register precision

The shown ISO color values apply for coldset on standard newsprint The register deviation should fall short of 0.3 mm and be less than 0.15 mm
ISO color space for coldset

The recommended color sequence is either CMYK
or KCMY
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ISO AM screen angle definition

The screen angle of the dominant color should be 135
Solid Ink Densities

For information only To give a reference for printer to help in printing
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Needs why to modify the 12647-3 standard

Technical reasons: Technological advances are changing both operational equipment as well as working methods Emotional reasons: Personnel, readers and advertisers are changing their behaviour, the attitude towards the medium newspaper has changed Competition: There is a large number of competing media (iPad, tablet, online), the decision to buy a product depends not only on the content but also on the overall appearance Change of the existing static production parameters to defining minimum levels
ISO 12647-3:2005 Reasons for change

Analog data handling is dying out: Films practically no longer used Plate exposure systems practically no longer used All definitions for Film can be removed (this involves several pages) in order to permit concentration on the printing forme Changes to proofing -> digital or softproof Clear incorporation of waterless offset
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ISO 12647-3:2010 -> Screens

Up to now, for example, 500 l/cm specified for imagers, in future 500 l/cm or more The specification for the 40 chain-dot screen changes to a bandwidth of 40 to 54 screen, with dot link-up at 40% and at 60% Non-periodic screens, (FM, frequency-modulated), other screen angles and other dot shapes are permissible It is expressly stated that, despite deviating settings, the printed final product must be ISO-conform, this concerns especially the tone value increase and color values
ISO 12647-3:2010 -> Coverage

Technical remark: FM screens have up to ca. 6% less tone value increase than AM screens. Theoretically, this can be corrected in the RIP. However, in case of major corrections this can lead to stepped gradations and fuzziness in smooth backgrounds. 240% coverage in print is the maximum (previously 260%), 220% is given as a reasonable target In case of a high ink laydown, the black share should be at least 90% (previously 85%)
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ISO 12647-3:2010 -> Preflight

The need for a PreFlight Check is specified for the first time Reason: no uniform standard exists for data production
Software: InDesign, CS1 bis CS5 Quark, V3.3 bis V8 Corel, V9 bis Suite X5 Pagemaker, V5 bis V7 MS Publisher 2007/2010 Scribus, V1 bis 1.3 Illustrator, V7 bis CS5 Freehand, V7 bis V11 Inkscape, V 0.47 Photoshop, V5 bis CS5 Gimp, V1 bis 2.7 Word, Power Point etc. Betriebssysteme: MAC OS X ff Mac OS bis 9.2 Windows XP, WIN 7 Linux, UNIX
Android, Chrome OS, Web-OS von HP
Fonts: TrueType Type 1 Opentype Type 3 CID-Fonts

BitMap Fonts
Kompression: ZIP, GIF, TIFF JPEG, JPEG 2000 JBIG2, LZW, CCITT
Bilder 1 Bit 2 Bit, 4 Bit 8 Bit 12 Bit, 16 Bit
PDF-Formate: PDF 1.2 PDF 1.3; JPEG, Device N PDF 1.4; Transparenzen PDF 1.5; Layer PDF 1.6; Opentype Fonts PDF 1.7; multiple files PDF 1.8 EPS: Level 1,2,3 PS: Level 1,2,3 DCS: 1 und 2
ISO 12647-3:2010 -> New: Gray balance

Calculation of the visual values of neutral gray Depending on paper white and maximal CMY application a* = a*paper x (1 - 0.85 x (L*paper - L*) / (L*paper L*cmy)) b* = b*paper x (1 - 0.85 x (L*paper - L*) / (L*paper L*cmy)) The 0.85 multiplication factor describes the visual perception of 85% of the actual paper white (put another way: 85% of the light is reflected, 15% absorbed)
Identical formula as in the offset standard 12647-2 Standard values can be published only for defined printing conditions and the accompanying ICC profile
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ISO 12647-3:2010 -> Printing condition

First-time definition of a printing condition for standard newsprint, with the objective of extending this Table in the future by additional conditions, e.g. SC or LWC paper
ISO 12647-3:2010 -> Newsshade

Overview of the target values for newsprint Unchanged tolerance values:
L*: 4 a*: 2 b*: 2
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ISO 12647-3:2010 -> L*a*b* Target values

Separate listing of the target values on black and white backing in order to avoid mixups Minor adaptation of the magenta b* value to -1 (old: -2), based on more than 15,000 WAN-IFRA measurements
ISO 12647-3:2010 -> Color tolerances

Definition of color tolerances both for the primary as well as binding for the secondary colors (previously only informative)
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ISO 12647-3:2010 -> Color register

Register deviation must be 0.2 mm The color register deviation is calculated by the theory of Pythagoras:
Lateral register (in micrometres) Circumferential register (in micrometres) Cyan (ref) 0 0 Magenta 50 0 Yellow 10 10 Black -50,00 -143,62
Largest deviation between two colors in register Largest deviation between:
175,00 M-K
50
a + b = c
0 -100 -50 0 50 100

Magenta Yellow Black Cyan (ref)
-50
-100
-150
ISO 12647-3:2010 -> TVI curve

Uniform 26% curve Calculation of the tone valuespecific increase by the polynomial function TVI (x) = 100*(a*x4 + b*x3 + c*x2 + d*x)
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ISO 12647-3:2010 -> Mid-tone spread

Simplification of the existing Table in order to facilitate understanding and specification of the measuring patches as 40/50 and 70/80 The mid-tone spread applies for all CMYK colors and is no longer confined to CMY as before
ISO 12647-3:2010 -> Densities

Densities serve only for information purposes, are not part of the standard and are based on empirical values ISO Status E, relative density (calibration on the paper), with polarizing filter: Cyan/Magenta/Yellow D 0,90 BlackD 1,10 ISO Status T, absolute density, without polarizing filter: Cyan D 0.90; Magenta D 0.90; Yellow D 0.85; Black D 1.05 Paper values C: 0,23, M: 0,24, Y: 0,27, K: 0,22 N.B.: Status T and Status E values are not comparable, there are major deviations especially in yellow
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INCQC 2012-2014
Categories and test charts Instructions and technical details
ISO 12647-3:2010 -> INCQC 2012-2014

The rules of the previous INCQC already integrated in part the planned innovations in the newspaper printing standard
Gray balance, but with existing values Mid-tone spread CMYK

Other new features of INCQC 2012-2014
Evaluation of the CMYK colors corresponding to the Delta E deviation in accordance with the ISO specification Evaluation of tone value increase at 40% (as to date) and additionally in the 70% measuring patch
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INCQC participation categories

4 categories allow the participation of nearly all newspaper titles, independent of the production process used. The evaluation criteria differ accordingly Category 1: Coldset-offset on newsprint Category 2: Heatset or UV offset on newsprint Category 3: Heatset or UV offset on SC or LWC paper Category 4: Extra category for newspaper printing on tinted paper or for printing processes outside of offset printing, e.g. flexo or digital printing The category assignment is done online up to the time the test begins
Cuboid version for 2012

46% of the participants in a survey preferred the Cuboid with 6x4 dots, as it is easiest to position this in the regular production run with the approval of the newsroom
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Development of the IFRA Cuboid

The Cuboid was designed at WAN-IFRA in close cooperation with international color experts Since 2009, the Cuboid has become established worldwide at newspapers as an accepted print test element the Cuboid can run in regular production its handling corresponds to that of a customer ad the consistent high quality is measured and judged under regular conditions time and cost-intensive special production runs with exceptional investment of resources are avoided
INCQC test chart IFRA Cuboid 2012

Single-column color filler ad, 42 x 28 mm With integrated color register measuring element Scaling must be avoided under all circumstance Version ID for each test month
Chaning version ID Color register measuring element Corner dots for measuring head positioning
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Color values of the IFRA Cuboid 2012

Positioning possible in both horizontal and upright format Scaling must be avoided under all circumstances
Positioning of the Cuboid

Anywhere in the main section as a filler ad, printed in the entire run or by means of a plate change after the regular production run No positioning in the fold, as that complicated the evaluation A different version of the Cuboid for each test month (January to March 2012) is made available for downloading
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Cuboid 2012 handling - Rules

Position like a customer ad, without additional ink trapping elements, etc. Do not change format Do not position in the fold, as otherwise the evaluation of the printed sample is adversely affected by set-off and soiling The reverse side of the Cuboid must be printed with newspaper-type contents Newspaper pages that only contain the Cuboid, have nothing printed on the reverse side, are printed on deviating paper grades or have different/missing pin holes on the page are evaluated as a special print with individual points subtraction
Application of the ISO standard

Newspapers are usually produced on web offset presses, but delivered untrimmed It is only by using control elements that it is possible to verify that technical criteria for production control, quality control and discerning customers have been satisfied Traditional control strips at the head and foot of the page: good from the technical point of view, in most cases rejected by the newsroom Ad-like test elements are widely accepted Printing test pages outside of production Image content-based systems
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Measuring instruments at WAN-IFRA

Spectrophotometer X-Rite EyeOne iO (measuring table)
angle of observation 2 light source D50 measuring geometry 45/0 black backing
Color register measurement with Techkon RMS 910
INCQC Instructions
Explanation of the INCQC 2012-2014 criteria
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Cuboid color target values in category 1

(coldset on standard paper)

(heatset/UV on standard paper)
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(heatset/UV on SC or LWC paper)
ISO tone value increase (TVI)

Category 1 26% curve
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Newsshade
The ISO-conform lightness of newsprint (newsshade) permits a good contrast and is therefore more readerfriendly. The color cast of the paper should be low. A sufficient opacity minimizes the show-through that is unavoidalbe in newsprint Evaluation: The target values less the ISO tolerances conttitute the minimum level in each caseje. A lighter paper than specified by ISO is rewarded by allocation of the full number of points
Newsshade tolerances
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Mid-tone spread
The mid-tone spread is one of the decisive quality factors for the color effect of a newspaper. In particular the widespread trend towards ink-saving methods via ICC profiles or independent InkSaver software is transforming the former skeleton black in the color image into a dominant factor. Due to this major significance, all inks in this evaluation are subject to the narrow ISO tolerances of mid-tone spread for colors.
Mid-tone spread
Report presentation
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Tone value increase

It is only by observing the dot gain specified in the ISO criteria that it is possible to clearly plan and verify the expected printed color result throughout the production chain, from draft to proof, preview and final printing. This is the only wayfor the graphic designer and customer to reliably predict the effect of the color in a printed ad. The following figures are valid only for category 1
Tone value increase

The graphic is based on the bases of 40% and 70%
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Gray balance
The gray balance allows neutral, pinting free of color casts. Early detection of color shifts and a fine tuning of the page The light paper gray is the individual, neutral color reference adapted for the eye. Because of the paper color, the gray axis is usually at an angle to the L* axis
Paper color Light gray, within the tolerance Medium gray, outside the tolerance Dark gray, within the tolerance Darkest CMY gray
Calculating the gray balance

(1) Calculation of the individual reference gray axis based on newsshade and dark CMY gray (2) Mathematical definition of the ideal a*b* values of the printed CMY light gray, medium gray and dark gray based on the L* value in each case (3) The measured a*b* values are compared to the individually calculated, ideal a*b* gray values The calculated color difference is Delta C* absolute The max. permissible deviation Delta C* absolute is 3
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Evaluation of the gray balance

The printed CMY gray tones are compared to the reference gray axis. The deviation is given as Delta C* absolute
Graphic representation of gray balance
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Color space
In the three-dimensional color space we calculate the color volume corresponding to the selected category in order to obtain a useful comparative value
Color conformity of the individual colors

Included in the standard is a definition for both primary and secondary colors in each case a target value, described as color gamut and defined by L*a*b* values The supplied colors must match these values in order to enable the printing plant to satisfy the required color standards in the printed product Only minor adjustments can be made by means of density variations during the printing process permit
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Calculating color conformity

The objective is to establish whether the color used achieves the minimum range If the color and print production exceed what the concerned standard demands, this theoretically constitutes a deviation but the full number of points are still awarded for this good result The measured color is compared to the Chroma (C*ab) of the reference color. If the measured value C*ab larger than or equal to the C*ab reference and the minimum lightness L* and color angle Hue (h*) angle are satisfied, then the achieved color gamut is larger and therefore better than the ISO standard If the color gamut within or less than the standard, an evaluation is done corresponding to the Delta E calculation
Example for color conformity
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Color register
The IFRA Cuboid contains the required measuring dots, with exactly defined intervals For the evaluation, we take the average of 3 measurements The register deviation should be less than 0.15 mm to obtain the full number of points
Color register
Calculation of the color register deviation is done based on the theory of Pythagoras: a + b = c
Lateral register (in micrometres) Circumferential register (in micrometres) Cyan (ref) 0 0 Magenta 50 0 Yellow 10 10 Black -50,00 -143,62
Largest deviation between two colors in register Largest deviation between:
175,00 M-K
50
0 -100 -50 0 50 100

-50
-100
-150
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General printing quality

Evaluation of two production copies from 2 different months Selected randomly from the submitted 3 x 10 copies Evaluation of the first 16 color pages of the newspaper Format-independent, broadsheet or tabloid Evaluation of the general printing is done based on criteria that every user can recognise (= user principle)
General printing quality

The marked-up copies and list of points are part of the evaluation report The first 16 full color pages of each newspaper title start out as 100% correct production Points are subtracted for detected shortcomings/defects = subtractive evaluation A weighted subtraction of points is done for each recognised criterion (e.g. printing plate edges) Independent of the intensity of the fault, points are subtracted only 1x for the page concerned
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Criteria General Printing Quality:

Color content of the newspaper Print process quality Color register Mechanical printing quality Image and graphic quality
General Printing Quality: Color content of the pages

Full number of points awarded only in case of 4-color production throughout the newspaper Points subtracted for 2c Points subtracted for b/w pages Reason: The error potential in 4c printing is much greater than in 2c or b/w printing
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General Printing quality: Print process quality and color register

Blanks in the print-out Overinking, underinking Density fluctuations Show-through Ink rub-off on hands and clothes Mis-register
Mechanical printing quality:

Set-off or smearing Impressions of draw rollers, rings, marks Hickies, picking, creasing Ghosting, doubling Printing plate scratches and plate edges Pin holes pulled -out or pin holes in image area Dirt stains, poor lateral register Poor ribbon register Toning, fuzziness
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Image and graphic quality

Ink piling in the image, image areas fill-in Color cast, color saturation inconsistent Poor screen quality (e.g. moir) Poor contrast range Image too bright or too dark Streaking, tonal value jumps Fuzzy images (not evaluated) Poor detail reproduction
Evaluation of GPQ (General Print Quality:

Each criterion is applied only 1 x per page
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Percentage breakdown of the evaluation criteria

Color conformity Delta E 14% Color space 4% Newsshade 9% Mid-tone spread 3% Gray balance 9% Dot gain 40% 3% Color register 9% Dot gain 70% 3% Gen. Print quality 46%
Consistently high-quality printing

The special aspect of the INCQC is that what must be achieved is not a one-time good result with a special production run, but that the regular daily production must demonstrably show a consistent and quantifiable high quality One of the categories (#4) is judged especially on whether it is capable of repeatably producing consistent and predictable results For advertisers, this has the major benefit that the expected printed results are plannable and usually do not require a specal check
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Success-table
For each test run a minimum number of points for the sum total of all criteria must be achieved The consistency check ensures that each individual criterion satisfies the standard during the test period The evaluation reports (January to March) are produced by the middle of the month in each case The final report for March with confirmation of Club membership is produced by June 2012 The evaluation of general printing quality is done based on 2 randomly selected copies from different months and from the readers point of view
Evaluation diagram
All criteria in the Table must be satisfied in both horizontal and vertical direction
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Evaluation procedure
In every competition month from January to March 2012 the IFRA Cuboid must be printed at least once under standardized conditions as part of a regular issue of your newspaper. The appropriate version of the IFRA Cuboid, duly indicated by name, must be printed for each competition month. The IFRA Cuboid version specified for each month must be printed. Failure to observe this rule will result in the participant concerned forfeiting points. Ten sample copies of each issue must be submitted on schedule for evaluation.
Preparations for a successful participation

Download IFRA test element Cuboid 2012 Webseite www.colorqualityclub.org Download, read and understand instructions In case of queries: phone or e-mail us Test-print the ad-like IFRA Cuboid Register by 17.10. and benefit from the possibility of a free evaluation by WAN-IFRA
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Color Quality Self Check

www.colorqualityclub.org Color Quality Self Check is free WAN-IFRA tool with color space calculator Online input on the WAN-IFRA website of values measured by the participant using a spectrophotometer The Techkon RMS is required for the color register measurement The report is sent out via e-Mail and is available for downloading The results are meaningful only if measuring was done in accordance with the ISO and the measuring instrument used is calibrated
Color Quality IFRA Check

www.colorqualityclub.org Color Quality IFRA Check is a pay-for tool with color space calculator and contains the identical measurement-based evaluation routines as the INCQC You submit the test prints to WAN-IFRA where evaluation is done in the laboratory under standardised conditions using calibrated measuring instruments The instruments used are the X-Rite Eyeone iO spectrophotometer for color and density measurement and Techkon RMS 910 for register measurement The final report is sent out by e-Mail
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Steps to success
1. Use suitable paper and checked inks 2. Ensure achievement of the required color values (color gamut taking into account density values) 3. Correct the tone value increase curves via the RIP 4. Maintain color register in print production 5. Set the general printing quality at a high level: by training and motivating personnel by technical maintenance of the production equipment by a willingness to allow proposals, changes and optimizations
Where to start?
Reproduction
PrePress
Press
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Where to start?
Reproduction
PrePress
Press
Where to start?
Reproduction
PrePress
Press
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Where to start?
Reproduction
PrePress
Press
Take care which PDF version you use

PDF 1.2: first wide spread version, big file size PDF 1.3: optimized for the printing industry, includes JPEG, Device N Colormanagement and good compression method PDF 1.4: feature transparencies, printable only after flattening PDF 1.5: new features Layer, JPEG 2000, 16 Bit Images, required conversion to run the files on the RIP PDF 1.6: new features Opentype fonts and N-Channel PDF 1.7 (ISO 32000-1): feature multiple files in one document PDF 1.8: Reference in preparation (www.adobe.com)
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PDF/X-Versions for the printing industry

PDF/X is a subset of settings to generate a printable file X-1a: only CMYK and Spotcolours X-3: CMYK and Spotcolours, but also RGB and Lab are allowed. Requires Colourmanagement All Fonts have to be embedded All Images without encryption and without LZW compression Defined BleedBox, defined TrimBox No JavaScript, no PostScript commands, no form fields No Transparencies, no Transfercurves
Why to go for Ink-Saving technologies

An average newspaper faces a consumption of 20.000 kg of black ink and a total of 50.000 kg of coloured ink per year per. Calculate 2 per kg, in this example were talking about 140.000 on Ink-costs per year The following presentation is about the possibility to eliminate approximate 10% to 15% costs with an investment in ink saving technology In the above mentioned example, appr. 14.000 to 21.000 less expenses can be achived means saved per year
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How is Ink-Saving working

Ink-Saving is a question of colour matching The sum of colour elements which addition results in grey will be replaced be black only GCR Grey Component Replacement Grey components:
70% Cyan + 70% Magenta + 70% Yellow = Dark Grey 30% Cyan + 30% Magenta + 30% Yellow = Light Grey
So: why printing grey with expensive coloured ink Solution: Printing grey with black ink only
Ink-Saving results on colour separation

No Ink saving, 350% TAC, Ink coverage Cyan Ink saving, 220% TAC, Ink coverage
Magenta
Yellow
Black
Composite
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Ink-Saving
Example from a big printing plant:
Ink consumption for 1.2 million copies in kg, 4/4 colour
C
without Ink Saver with Ink Saver difference
M 408,7 264,6 -144,1
Y 852,6 755,0 -97,6
K 268,2 346,0 +77,8
Total 1859,4 1597,7 261,7 14,09 %
329,9 232,1 -97,8
% saving
Ink-Saving colour effects!

No visually observable effect, people watching the printed image do not see any difference. Colorimetric values in the composite image remain unchanged. Achromatic areas, 3 color grey areas resulting of similar contingents of Cyan, Magenta, Yellow (e.g. 30% Cyan, 30% Magenta, 30% Yellow) are converted to Black Heavy changes in the single colour separations:
Cyan, Magenta, Yellow are reduced Black is increased.
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InkSaving Methods
ICC-Profiles FM (Frequence-Modulated) screening DeviceLink standard (=static) ICCprofiles Vendor-specific static DeviceLink profile Real-time dynamic DeviceLinking and immediate recalculation depending on specific data analysis per single file.
InkSaving by using ICC-profiles

Using ICC Colour management requires investment in ICC-profiles (some are free, like IFRA ISOnewspaper26v4.icc), usage during RGB-CMYK conversion requires manpower and know how
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InkSaving by FM
Embedded in the RIP
(frequence modulated)
screening
Using FM-screening or Hybrid screening technology requires an investment in screening technology, mostly for multiple RIPs Lots of suppliers are on the market without any claim on completeness: Adobe Brilliant Screen, Agfa Sublima, Kodak Staccato, Heidelberg Diamond Screening Results vary, some user confirm Ink-savings with FM, but there are also some discussions about it. Individual testing is required in any case.
FM (Frequence modulated) screening

Plenty of FM rasterelements are closely arranged to each other. They absorb more light than a comparable amount of standard AM rasterelements. This results in a lower area of printing dots, which requires in the end less ink
AM
FM
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InkSaving by DeviceLink profiles

DeviceLink Profiles, depending on standard ICC which can be embedded in applications like Photoshop specific DeviceLink profiles which connects Input CMYK channels directly with output CMYK channels, without the loop to L*a*b* Colour Server DeviceLink technology dedicated colour server with applied vendor specific static device link profiles dynamic real-time device linking by analyzing the file, generating a temporary DeviceLink profile (Input-Output profile) and immediate recalculating the colour channels.
GCR
Example color
No UCR/GCR Moderate GCR Strong GCR
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Device Linking -
Preparation for specific output devices
ICC-based or dynamic server based recalculation of the values of the different colour channels
Devices for Sheet Fed printing
Link to
Devices for Newspaper
Cyan Magenta Yellow Black
Cyan Magenta Yellow Black

Benefits of Ink-Saving
Between 10 and 20% less consumption (and also cost reduction) of expensive coloured Ink Better printability of paper and stable grey balance Reduces colour variations during the print run Better drying because of less ink has to penetrate the paper Less smearing on guide and draw rollers Reduced Fountain solution, reduced Ink mist Less shine through Smooth process in mailroom Less waste in total
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Workflow with Inksaving tools

Inksaving can happen on single elements in case of usage with standard applications like Photoshop Inksaving can happen on a stand alone Colour Server, running the whole page before ripping Inksaving can be part of the RIP in case of using ICCprofiles or FM-screening
Reproduction
Consistent application of color management in processing internal and external data Regular calibration of monitor, proof-printer, scanner Application of IFRA ISO ICC profile contains: ISO color space Color of standard newsprint 240% total inking Tone increase curves with 26% Category 2, 3, 4: Use of improved/tinted paper and/or dryer: use special ICC profiles
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RIP
Proofing
LAB LAB
Generate profile for proofing system Use ISOnewspaper26v4.icc for absolute colorimetric proofing:
File
CMYK data
on newsprint (possibly simulation) include media wedge for analysis

Use DeviceLink to avoid Lab conversion
RIP
L*a*b* colour system

CIELAB (1976) Exact and easier for representation
L= 0 to 100 a= -128 to 127 b= -128 to 127
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3D model of the L*a*b* colour space

L = 50 a=0 b = -128 L = 33 a = +48 b = -27
-a green white, L
+b yellow
+a red
-b blue
black
Calibration charts and targets - Examples
IT8.7/2 target for scanner profiling
IT8.7/3 target for press profiling
Gmg colorchecker chart for Digital camera profiling

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Tone value increase curve

The 26% curve is based on worldwide agreement Newspaper customers have the possibility, by means of a proof, to simulate and judge the actual appearance of the printed ad in advance This offers international advertisers, such as Mercedes, Toyota, Dell, CocaCola, etc., the opportunity to plan the color effect Color content can be published with a comparable standard of quality in different newspapers worldwide This means that specific advertising messages can be communicated not only via the text, but also through images and graphics
Tone value increase - Factors

Screen definition, AM or FM Paper properties Plate and imaging method (positive/negative) Printing blanket, compressing, cylinder packing Solid density (ink application, ink layer thickness respectively) Printing speed, with/without drying Humidity, climatic conditions Ink and inking system temperature Fountain agent: pH, conductivity, hardness, temperature
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Mid-tone spread
Describes the difference in tone value increase between the process colors in the mid-tone (40%) Correction in the RIP only after stabilisation of the printing process
The smaller the better are grey balance and color reproduction
Good result - consistent
Negative inconsistent and too high

RIP settings to control the TVI

Imaging resolution Screening resolution Dot shape Screen angle measured on paper yellow cyan magenta black (K) Harlequin: Extra Grey Levels Harlequin: Precision Screening Harlequin: Clear Centred Rosette Harlequin: Override Applications 0 15 75 135 ON ON OFF ON
1270 dpi 40 l/cm chain-type dot (Elliptical P) horizontal (3 oclock) anti-clockwise anti-clockwise anti-clockwise Value = 1024
Harlequin RIP: (bear in mind: 0 at 12 oclock)
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Controlled reproduction and print process:

Reproduction settings Controlled platemaking RIP settings Generation of tonal value increase curves (TVI) Mid-tone spread and grey balance Measuring and optimising colour space Measuring and improving colour register Optimising density settings
Plate exposure
1. Laser intensity (continuous tone wedge) 2. Check development (Thermostrip) 3. Exposure quality (CtP Testform) 4. Linearisation (RIP) 5. Continuous control
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Laser intensity control

Problem: dot loss in print
Example: AGFA N91 and UGRA/FOGRA control wedge
AGFA: with full through-hardening, promised up to 400,000 impressions (in practive average is 250,000) Step 3 covered in UGRA continuous tone wedge (N91V: step 2) No difference between step 2 and 3 (or N91V step 1 and 2 respectively) To date, the continuous tone wedge offers the best possibility to test the correct through-hardening
Continuous tone wedge to control Laser intensity

e.g. UGRA/FOGRA 1982, Fuji, Stouffer, Pay attention to differences in continuous tone steps To be used with photopolymer and silver plates Check if plate batch or chemistry were changed The continuous tone wedge is the only test element that provides information about hardening Imager should offer test mode
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Photopolymer plates
Photopolymers are negatively exposed: exposed areas are hardened with laser light and pre-heat Laser intensity, plate sensitiveness, and plate development determine the number of possible impressions High laser energy = high mileage (hopefully) Excessive laser energy: Gradation loss (tone value increase) Line elements and type become thicker
Developing machine
The following must be checked and documented: Pre-heat, e.g. more than 110 C pH-value Pre-wash, fresh water supply, e.g. 750 ml/m2 Developer temperature, e.g. 24 C 2 C Brush speed 130 rpm 20 rpm Gumming 225 mg/m2 50 mg/m2
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Developing machine
Frequent adjustment of brushes
Exposure quality
Control tools: Testforms: Solid form 50% form Control wedge form: Tone values Laser focus Resolution Plate measuring instrument e.g. Techkon DMS
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Exposure quality
Check exposure consistency across the full plate Check brush pressure Every day, every laser (ideally)
Exposure: What must be compared?

Use Siemens star to check 9 positions of each plate and laser focus Each imager with its 2 plate positions Tone value precision in an imager: 2% Deviation imager to imager: 2%
Imager 1
Imager 2
R
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Minimize differences between imagers
All laser are different - and they age Avoid different laser manufacturers or different technical specifications Lasers should have a similar level of utilisation When one laser is replaced, its recommended to exchange others also
Linearisation in the RIP

Calculate average values after matching the imagers and positions All imagers should be calibrated with just one RIP curve Several RIP curves are recommended if different types of imagers and technologies are used
15,0
10,0
5,0
0,0 0 5 10 20 30 40 50 60 70 80 90 100
-5,0
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Continuous control
Dependent on technology (photopolymer, thermal, silver, UV) The control wedge permits the operator to simply and quickly carry out random visual checks on important properties Control wedge outside the printable area on each plate For example: AGFA DigiControl
Where appropriate, use closed loop control system (e.g. AGFA: Afirma, Nela: PQM+, 2B: PQCS) (see IFRA SR 2.32)
Continuous control: e.g. by AGFA DigiControl

Gray dots for positive plates (Lithostar, Thermostar): neutral from 2x2 Negative plates: display of working point First adjust to right laser power Image the DigiControl with the right laser power on the correct position Working point is e.g. C (see example) Move to left side (e.g. B): over exposure or under development Shift to right side: dense imaging or over development
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AGFA DigiControl
Reasons for shifts: Changes in the laser energy Becomes darker as laser energy increases Focus changes Details become darker if focusing fades Becomes darker as developer ages
Continuous control: Siemens Star
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Plate parameters
Plate dimensions: ISO 12635:2008 Length Width standardised Thickness: 0.28 mm +/- 0.01 mm Parallelism Influence of roughness on water distribution
Surface of a new plate
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Plate after 135000 impressions (under normal conditions)
Plate after 60000 impressions (under poor conditions)
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Dot loss during print production

Not well exposed border disappears in print Tonal loss can not be avoided during print run No standard available: When is a plate unusable? Influences on plate durability from the printing procedure: Pressure in the printing gap Printing blanket Materials (ink, paper) Chemicals (water additives, cleaners)
Dot loss in print

Lifecycle of a plate
80
70
60
50
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Reasons for dot gain

Optical dot gain: Greatest share of dot gain Paper surface Light intensity Dot size (l/cm) Dot shape
Paper
Paper
Reasons for dot gain

Mechanical dot gain: Ink film thickness Printing blanket (thickness, hardness) Nip pressure Ink (viscosity, emulsification) Paper properties (roughness, volume, hardness) Absorption behaviour (paper, ink) Color sequence
Plate
Print
Blanket squeezin Raster dot g Blanket Paper surface
Paper
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Calculation of dot-gain curves

Preconditions: Exposure and development ok Tone loss of the plates is known and stored in the RIP Target densities are known (maximum print contrast) Printing towers adjusted: no slurring/doubling, provision of forme rollers and film roller, blanket thickness, etc. Use stable plate phase of plates(>6000, <40000) for test prints
Test print 1 document status

Use linearised plates 50% file = 54% on plate before printing = 50% between 6000 and 40000 copies Note materials used (film, type of plate, plate thickness, ink, water additives, printing blankets, etc.) Print correctly: Densities Ink-water balance Calculate tonal increase curves after e.g. 6000 impressions and at least 5 hours drying
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Test print 1 Non-acceptable dot-gain curves of several printing units

50 45 40 35 30 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 Tone steps from 0 to 100%
Test print 2
Use RIP tone curves for platemaking Print correctly: Densities Ink-water balance Several prints are necessary to cover all towers and to have a statistical basis Check tone curves after e.g. 6000 impressions and at least 6 hours drying time
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Dot-gain compensation:
Input the required ISO 26% dotgain curve in the RIPsoftware, e.g. Harlequin Calibration Manager (intended press) for CMYK Example: 50% + 26% = 76%
Dot gain compensation: actual press

Input the average tone increase from test print 2 Fingerprint (actual press) One curve for all colors or four curves (for Cyan, Magenta, Yellow and Black each) Example: 50% + 32.7% = 82.7%
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Dot-gain compensation: activate settings

Select calibration for the linearised plate Select ideal press (ISO 26 curve, intended press) Select actual press RIP calculates the correct tone values based on these 3 calibration curves Example: 50% file = 47% Film = 53% Plate = 76% Paper
Test print 3
Verify that all parameters are correct Print again correctly 26% dot gain curve must be achieved (+/- 2%)
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Check dot gain curves

Tone increase convergence between the towers by: Different printing blankets (hardness, thickness) Correct contact pressure Same materials (paper, ink, fountain solution additives) If tone increase is generally too high or too low, adjust screen definition as necessary Cortina FM screen
Grey balance
Optimisation in 0,5 % steps of the dot gain compenasation curve
D t g in in% o a
30
25,00 25
21,33
20
20,67
15
10
0 0 10 20 30 40 50 60 70 80 90 100
CMY = 2,33% CMYK = 4,35%
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Optimising gray balance

Original Cuboid CMY gray patches composition in accordance with ISO: Quarter-tone (10% C, 8% M, 8% Y) Mid-tone (30% C, 24% M, 24% Y) Three-quarter tone (50% C, 42% M, 42% Y) With Ink Saver software, black replaces CMY values Grey balance should be easier to achieve: C* absolute < 3
Color gamut
Size of required color gamut is dependent on INCQC category Better with sufficient paper white and optimized color densities Insufficent results to be discussed with the Ink supplier
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Measure color register

Diagonal mis-register should be < 0.15 mm (max.: 0.30 mm) on all pages Measuring elements Visual Measuring instrument
-100 -50
50
0 0 50 100
-50
-100
-150
Optimise color register

Fluctuations due to:
Platemaking Fan-out: change of web speed Fan-out: different swelling behaviour of paper Web tension Wear & tear (e.g. register pins, plate locks) Operator (plating-up, use image corrector)
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Optimise color register

Advantages due to:
RIP scaling Within the plate Dependent on the cylinder position FM screen (only optical advantage) Video alignment at plate-making Camera adjustment, satellite printing units, waterless Image corrector (manual, speed-dependent, closed loop) Automatic plate changing system
Set fan-out to production speed

Press control
Preset based on RIP data corresponding to actual materials
Start-up curves for typical material combinations 1. Ink ductor curve (Cortina: temperature) 2. Fountain solution curve
Different curves for warm/cold press Different curves for typical material combinations (plates, ink, paper, fountain solution additive, blankets)
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Ink ductor curves example

New ink ductor curves 09.02.2005
45 40 35 30 Opening Value [%] 25 20 15 10 5 0 1 -5 Speed [R/h] 15. Black 16. Cyan 17. Magenta 18. Yellow
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Set ink ductor curves

1. 2. 3. 4. 5. 6. 7. Check inking system and ink duct Print waterless using dummy plates Medium ink key opening Copy removal in steady state at certain speeds (8, 12, 25, 40 revs./h) Evaluate densities Set curves Test new curves
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Damping system curves example

New water curves, 09.02.2005
100 90 80 70 Opening Value [%] 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Speed [R/h] 15. Black 16. Cyan 17. Magenta 18. Yellow
Set damping system curves

1. 2. 3. 4. 5. 6. 3 testformes: low, medium, high ink coverage Use medium ink key opening/presetting data Copy removal in steady state at certain speeds (8, 16, 24, 32, 40 revs./h) Find setting above the point of smearing If there is no special cold-start adjustment: apply a little more water at start-up speed Test interaction of all curves
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Speeding up the Press

Carry out pre-inking Allow for press reaction time Use densitometer for ink setting Read back only correct values (correct densities, correct speed) for adjusting the press presetting
Thank you for your attention.
Roland Thees, Industrial Engineer Project Manager Consulting WAN-IFRA GmbH & Co. KG, Darmstadt Tel.: +49 6151 733 788 roland.thees@wan-ifra.org www.wan-ifra.org
2011 WAN-IFRA Roland Thees
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23.11.

2011 WAN-IFRA Roland Thees, Page 2

Topics of the INCQC Tutorial

2011 WAN-IFRA Roland Thees, Page 3

Agenda 1. December 2011

2011 WAN-IFRA Roland Thees, Page 4

(as of November 2011)

2011 WAN-IFRA Roland Thees, Page 5

Objective of the INCQC

2011 WAN-IFRA Roland Thees, Page 6

Benefits of INCQC participation

Reasons for INCQC participation

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2011 WAN-IFRA Roland Thees, Page 9

2011 WAN-IFRA Roland Thees, Page 10

INCQC 2012 Time Schedule

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2011 WAN-IFRA Roland Thees, Page 12

Features of INCQC 2012-2014

2011 WAN-IFRA Roland Thees, Page 13

ISO for the news publishing industry:

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2011 WAN-IFRA Roland Thees, Page 16

Advantages of applying the standard

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Aim of a standardized newspaper production

Standards prevent prints in different visual appearance

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Advertisers problem with Newspapers

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Core topics of the ISO 12647-3 standard

Newsshade for ISO standard paper

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ISO color values and register precision

2011 WAN-IFRA Roland Thees, Page 23

ISO color space for coldset

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ISO AM screen angle definition

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Solid Ink Densities

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Needs why to modify the 12647-3 standard

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ISO 12647-3:2005 Reasons for change

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ISO 12647-3:2010 -> Screens

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ISO 12647-3:2010 -> Coverage

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ISO 12647-3:2010 -> Preflight

Fonts: TrueType Type 1 Opentype Type 3 CID-Fonts

Bilder 1 Bit 2 Bit, 4 Bit 8 Bit 12 Bit, 16 Bit

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ISO 12647-3:2010 -> New: Gray balance

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ISO 12647-3:2010 -> Printing condition

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ISO 12647-3:2010 -> Newsshade

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ISO 12647-3:2010 -> L*a*b* Target values

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ISO 12647-3:2010 -> Color tolerances

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ISO 12647-3:2010 -> Lab* Target values