Pancyprian TS Graphic Arts III Π.Κ. cheat sheet

Capture resolution: scan at 2× the final screen ruling (lpi) at final size; for 150 lpi output use 300 ppi images at 100% scale.

Bleed standard: 3 mm bleed on all trimmed edges; safe margin at least 5 mm inside trim for text and critical elements.

Trapping: spread light colours into dark ones; typical trap width 0.1–0.25 mm for offset, 0.3–0.5 mm for flexo, 0 for digital toner printing.

Overprint rules: black text overprint by default; rich black (e.g. 60C 40M 40Y 100K) must knock out, never overprint.

Imposition: sheetwork (work-and-turn/work-and-tumble) for perfecting presses; cut-and-stack or step-and-repeat for packaging; check gripper margin (commonly 8–12 mm).

PDF/X-4 allows live transparency and ICC output intents; PDF/X-1a requires flattened, CMYK/greyscale only and no transparency.

Total area coverage limit: coated offset 300–330%, uncoated 260–300%, newsprint ~240%, inkjet/digital toner lower per device spec.

Font embedding: embed all fonts or convert to outlines; check for missing links and RGB objects before output.

Output proofing: soft proof uses the output ICC profile with black point compensation; hard proof must match ISO 12647-2 tolerances.

Offset: dampening solution pH 4.8–5.5, conductivity 800–1200 µS/cm; ink/water balance is the first make-ready variable.

Offset cylinder packing: blanket-to-plate pressure typically 0.10–0.15 mm squeeze; excessive pressure causes dot gain and plate wear.

Screen printing: mesh count determines ink deposit; stencil thickness (EOM) plus mesh open area set wet film; squeegee hardness 60–80 Shore A.

Flexography: anilox cell volume (cm³/m²) and line screen set ink transfer; doctor blade angle typically 60°; plate durometer 50–70 Shore A.

Digital toner: fuser temperature and pressure govern gloss and adhesion; calibrate with linearisation plus ICC profile per substrate.

Quality control: register tolerance ±0.1 mm sheetfed; colour measured against ISO 12647-2 ΔE tolerances; densitometry for solid ink density (SID).

Make-ready sequence: plate/blanket mount, ink and damp setting, register, density, then colour approval; record waste sheets per job.

Ink drying: oxidation for sheetfed offset (hours), heatset evaporation, UV curing (instant), and water-based absorption for flexo porous substrates.

Paper grammage (g/m²) × sheet area (m²) = weight per sheet in grams; ream weight derives from this for cost calculations.

Grain direction: fold parallel to grain for clean folds; grain long/short affects stiffness, dimensional stability and register on press.

Paper conditioning: store at 20–23 °C and 45–55% RH; equilibrate stock 24 h before printing to avoid wavy edges and misregister.

Coated vs uncoated: coated gives higher gloss and lower ink absorption; uncoated gives better writeability and ink penetration.

Ink types: oxidative sheetfed, heatset web, UV/EB (no solvent, instant cure), water-based flexo, plastisol screen inks for textiles.

Offset plates: conventional, CTP thermal (830 nm), violet (405 nm); processless plates need no chemical development.

Blankets: compressible vs conventional; check thickness tolerance and torque; store away from UV and ozone.

Adhesives: EVA hot melt (low cost, poor heat resistance), PUR (strong, moisture-cure), starch for corrugated, cold glue for spine binding.

Cutting: guillotine clamp pressure 30–60 bar depending on stock; knife angle typically 21–24°; keep cut margin at least 3 mm from printed content.

Folding: buckle folders handle up to ~16 pp; knife folders for heavy stock; fold tolerance ±0.5 mm; score heavy stock ≥200 g/m² before folding.

Binding: saddle stitch for 8–64 pp (multiples of 4); perfect binding for thicker books; spiral/wire-o for lay-flat; check creep/shingling in saddle stitch.

Laminating: BOPP gloss/matt 15–30 µm; corona treatment or primer needed for adhesion; watch curl balance (matt both sides or balanced film).

Die-cutting: cutting rule height 23.8 mm standard, creasing rule 23.2 mm; make-ready with counter and stripping; check nick and waste removal.

Packaging: FEFCO/ECMA standard box styles; crease depth and score width must match board thickness to avoid cracking.

Foil stamping and embossing: temperature, dwell and pressure; foil adhesion varies with substrate and foil grade.

Quality: check fold cracking, spine squareness, trim cleanliness, and delamination after lamination.

CIE Lab*: L* = lightness 0–100, a* = green(−)/red(+), b* = blue(−)/yellow(+); device-independent reference for colour measurement.

ΔE formulas: ΔE76 (simple Euclidean), ΔE94 (weighted), ΔE2000 (most perceptual); commercial tolerance often ΔE2000 ≤ 2–3 for proofing.

Colour models: RGB additive (screen), CMYK subtractive (print), spot/Pantone for brand colour; convert with rendering intent (relative colorimetric for logos, perceptual for photos).

Density: solid ink density (SID) controlled by densitometer; target values per ISO 12647-2 (e.g. K ~1.45–1.55, C ~1.30–1.40 depending on process).

Dot gain/TVI: midtone tone value increase typically 12–20% for sheetfed coated; compensate in plate curves.

Grey balance: CMY must produce neutral grey; check with grey patches and balance to reference.

Proofing: contract proof must be made with output ICC profile and measured; verify ΔE and density against reference.

Metamerism: colour match under D50 (ISO standard viewing) vs D65; always evaluate under controlled lighting.

Machinery guarding: interlocked guards on all rotating parts; emergency stops accessible within reach; lockout/tagout before maintenance.

Chemical safety: SDS (Safety Data Sheet) available for every chemical; GHS pictograms and hazard statements displayed.

Solvent exposure: workplace exposure limits for organic solvents (e.g. toluene, IPA); local exhaust ventilation required; monitor VOC levels.

IPA and dampening: reduce IPA use with alcohol-free dampening; store in closed containers away from ignition sources.

Waste: separate paper, plates, ink containers, solvent waste; waste hierarchy (reduce, reuse, recycle, recover, dispose).

Ink and toner disposal: waste ink as hazardous waste; toner cartridges returned to supplier or recycled per local rules.

Noise and dust: hearing protection above 80 dB(A); dust extraction in guillotine and folding areas.

Fire safety: solvent storage in fire-rated cabinets; no smoking; appropriate extinguishers (CO2/foam, not water on electrical).

Job costing formula: cost = materials + labour + machine time + overheads + waste + margin; quote per 1000 or per unit.

Machine hour rate = (annual machine cost + operator + energy + space) ÷ annual productive hours.

Waste allowance: add 2–5% for sheetfed offset, 5–10% for short-run digital, and extra for make-ready and finishing.

Scheduling: forward vs backward scheduling; critical path (CPM) identifies the bottleneck; Gantt chart tracks machine loading.

Capacity: press speed (sheets/h) × available hours × utilisation = theoretical output; subtract make-ready and downtime.

Stock control: reorder point = average daily use × lead time + safety stock; FIFO rotation for paper and ink.

Layout: material flow from prepress → press → finishing → dispatch; minimise travel distance; separate clean and dirty zones.

KPI: OEE = availability × performance × quality; track waste %, on-time delivery, rework rate.

ISO 9001: quality management system; document procedures, records, corrective actions and internal audits.

ISO 12647 series: process control for offset (part 2), proofing (part 7), screen/flexo (parts 5/6); defines colour and density targets.

Job ticket/docket: contains specification, quantity, substrate, colours, finishing, delivery date and approval signatures.

Approval: signed contract proof is the legal reference; changes after sign-off require a new proof and cost adjustment.

Technical documentation: SOPs, calibration records, maintenance logs, ink/paper certificates and colour measurement reports.

Traceability: batch/lot numbers on paper and ink allow recall and complaint investigation.

Customer complaint handling: root cause analysis (5 Whys, fishbone), corrective and preventive action (CAPA), record closure.

Data protection and confidentiality: customer artwork and brand assets are confidential; follow GDPR for personal data.

Colour conversion: use relative colorimetric with black point compensation for logos; perceptual for photographic images to preserve detail.

Image resampling: downsample with bicubic/bilinear; never upsample beyond 120% of original resolution without accepting quality loss.

Transparency flattening: PDF/X-1a flattens transparency; check for stitching artefacts and thin white lines at object boundaries.

Imposition for packaging: step-and-repeat, gang run, and rotation to align grain; check gripper and lay edges on the sheet.

Variable data: PDF/VT or PPML for personalised jobs; verify data merge fields and barcode readability (ISO/IEC 15415 grade).

Preflight checks: missing fonts, RGB images, low-resolution images, overprint settings, bleed, and spot colour naming.

Barcode and QR: minimum module size and quiet zone; verify with a verifier to ISO/IEC 15416 grade C or better.

Colour management: assign source profile, convert to output profile with intent; embed output intent in PDF/X-4.

Offset register: circumferential, lateral and diagonal adjustments; check register marks at all four corners.

Ink rheology: viscosity and tack affect transfer; tack sequence from first to last unit should decrease to avoid back-trapping.

Dampening: alcohol-free systems need higher roller speed and careful conductivity control; check pH drift during run.

Flexo: anilox wear reduces cell volume; measure with a cell-volume gauge; doctor blade wear causes streaks.

Screen: off-contact distance 1–3 mm; squeegee angle 60–75°; snap-off affects dot sharpness.

Digital: fuser and transfer belt condition; calibrate per substrate and re-check after 500–1000 sheets.

Quality control: SPC charts for density and ΔE; stop the press when trend exceeds control limits.

Press maintenance: daily lubrication, weekly blanket wash, monthly roller inspection; log all interventions.

Paper strength: tensile and tear strength depend on fibre orientation; grain direction affects fold and die-cut quality.

Moisture content: paper equilibrium moisture ~5–7%; changes cause curl, wavy edges and register drift.

Ink adhesion: test with tape pull or rub test; poor adhesion indicates insufficient drying or surface energy mismatch.

Surface energy: substrates need ≥38 dyn/cm for good ink/toner wetting; corona treatment raises surface energy.

Plate care: store plates in dark, humidity-controlled area; handle with gloves to avoid fingerprints and scratches.

Blanket storage: hang or lay flat; avoid compression and UV; check for swelling after solvent wash.

Adhesive selection: match to substrate, service temperature and bond strength; PUR for spine, hot melt for cartons.

Consumable cost: track ink usage per m² and plate cost per job to control job costing.

Guillotine: check knife sharpness; blunt knife causes crushing and inaccurate cuts; maintain cutting stick.

Folding: buckle folder roller pressure and fold plates; static electricity causes misfeeds; use ionisers.

Perfect binding: spine preparation (roughening) and glue application thickness; cover nipping pressure affects squareness.

Saddle stitching: check stitch position and leg length; creep compensation for thick sections.

Die-cutting: make-ready with counter, stripping and blanking; check nick size and waste removal.

Lamination: check adhesion, bubbles and curl; matt/gloss balance and film tension.

Packaging: verify crease quality, box squareness and stacking strength; test with compression and drop tests.

Post-press QC: dimensional accuracy, fold cracking, trim quality, and final visual inspection against approved proof.

Colour spaces: sRGB, Adobe RGB, ProPhoto RGB; gamut differences affect conversion results.

Rendering intents: perceptual, relative colorimetric, absolute colorimetric, saturation; choose based on content.

Measurement geometry: 45/0 or 0/45 for print; sphere spectrophotometer for special effects; calibrate instrument daily.

White point: D50 for print standard; D65 for display; mismatch causes metameric failure.

Tolerance: ΔE2000 ≤ 2 for contract proof; ΔE ≤ 3–5 for production acceptance depending on customer.

Grey balance and TVI: control with grey patches and plate curves; verify with densitometer and spectrophotometer.

Soft proofing: calibrate monitor to ISO 12646 (D50, 80–120 cd/m², gamma 2.2 or L*); use viewing booth.

Colour deviation: record measurement data per job; use SPC to detect drift and correct before rejection.

Risk assessment: identify hazards, evaluate risk, implement controls, review; document for each machine and chemical.

COSHH/REACH: assess chemicals, obtain SDS, substitute hazardous substances where possible.

Ventilation: local exhaust for solvent and dust; check airflow and filter condition regularly.

PPE: gloves, goggles, respirators for solvents and dust; train workers on correct use.

Waste segregation: paper, cardboard, plastic film, metal plates, ink and solvent waste; label containers.

Environmental permits: check local regulations for VOC emissions, waste disposal and water discharge.

Energy: switch off idle machines; optimise compressed air and lighting; monitor consumption.

Emergency: spill kits, eyewash stations, first aid; drill and record incidents.

Cost estimation: material cost = area × grammage × price/kg; add ink, plates, labour and finishing.

Break-even: fixed costs ÷ (price − variable cost per unit); use to set minimum order quantity.

Scheduling: use ERP/MIS to load presses; prioritise by due date and setup efficiency.

Setup reduction: SMED principles; standardise job tickets and pre-set tools to cut make-ready time.

Inventory: ABC analysis; keep high-use consumables in stock; avoid overstock of special substrates.

KPI: waste %, OEE, on-time delivery, rework rate; review weekly and act on trends.

Layout: flow from raw material to dispatch; minimise handling and travel; separate clean and dirty areas.

Cost control: track actual vs estimated; analyse variances and update rates.

Quality system: ISO 9001 requires documented procedures, records, internal audits and management review.

Process control: ISO 12647 defines target values for density, TVI, grey balance and register.

Job documentation: job ticket, approved proof, colour measurement report, delivery note and invoice.

Traceability: batch numbers on substrates and inks; records of machine settings and operator.

Complaint handling: root cause analysis, corrective action, verification of effectiveness, record closure.

Confidentiality: protect customer artwork and data; follow GDPR and contractual obligations.

Training: keep records of operator competence and refresher training.

Audit: internal and external audits; prepare documentation and close non-conformities.

PDF standards: PDF/X-1a, PDF/X-4, PDF/A for archiving; PDF/VT for variable data.

Colour conversion: use ICC profiles; check black point compensation and rendering intent.

Image resolution: 300 ppi at final size for 150 lpi; 600 ppi for fine detail or packaging.

Overprint and trapping: check in preflight; use trapping engine with correct widths.

Imposition: sheet layout, gripper, bleed, and cut marks; verify with a proof plotter.

Barcode: verify grade and quiet zone; test with scanner before print.

Preflight checklist: fonts, images, colours, bleed, overprint, resolution, page size.

Output: send PDF/X-4 with output intent; verify with preflight report.

Offset: ink/water balance, plate/blanket pressure, register, density; check with densitometer.

Flexo: anilox volume, plate durometer, doctor blade, drying; check with microscope.

Screen: mesh, stencil, squeegee, off-contact; check ink deposit and dot sharpness.

Digital: fuser, transfer, calibration; check with spectrophotometer.

Quality: SPC charts, control limits, corrective action.

Maintenance: daily, weekly, monthly tasks; log interventions.

Safety: guards, emergency stops, lockout/tagout.

Waste: record and minimise; recycle.

Paper: grammage, grain, moisture, strength; store in controlled conditions.

Ink: viscosity, tack, drying; match to process and substrate.

Plates: CTP, thermal, violet, processless; store correctly.

Blankets: compressible, conventional; check thickness and torque.

Adhesives: EVA, PUR, starch, cold glue; match to application.

Cost: track usage per job; control waste.

Quality: test adhesion, strength, and printability.

Safety: SDS, storage, disposal.

Cutting: guillotine, clamp pressure, knife angle; check accuracy.

Folding: buckle, knife; check fold quality and cracking.

Binding: saddle stitch, perfect, spiral; check strength and squareness.

Laminating: BOPP, adhesion, curl; check quality.

Die-cutting: rule height, crease, stripping; check accuracy.

Packaging: FEFCO styles, crease, strength; test.

QC: dimensional, visual, functional.

Safety: guards, lockout/tagout.

CIE Lab*: device-independent; measure with spectrophotometer.

ΔE: 76, 94, 2000; tolerance depends on application.

Colour models: RGB, CMYK, spot; convert with ICC profiles.

Density: SID, TVI, grey balance; measure and control.

Proofing: contract proof, soft proof; verify with measurement.

Metamerism: D50 vs D65; control lighting.

Gamut: check with profile; use rendering intent.

SPC: track ΔE and density; act on trends.

Guards: interlocked, emergency stops; lockout/tagout.

Chemicals: SDS, GHS, ventilation, PPE.

Waste: segregate, label, dispose; follow hierarchy.

Solvents: exposure limits, monitoring, substitution.

Noise/dust: protection, extraction.

Fire: storage, extinguishers, drills.

Training: records, refresher.

Audit: check compliance and close gaps.

Costing: materials, labour, machine, overheads, waste, margin.

Machine hour rate: annual cost ÷ productive hours.

Waste allowance: 2–10% depending on process.

Scheduling: forward/backward, CPM, Gantt.

Capacity: speed × hours × utilisation.

Inventory: reorder point, FIFO, ABC.

Layout: flow, minimise travel, separate zones.

KPI: OEE, waste %, on-time, rework.

ISO 9001: procedures, records, audits, corrective action.

ISO 12647: process control targets.

Job ticket: specification, approval, delivery.

Approval: signed proof is legal reference.

Documentation: SOPs, calibration, maintenance, certificates.

Traceability: batch numbers, records.

Complaints: root cause, CAPA, closure.

Confidentiality: GDPR, customer data.

Resolution: 300 ppi at final size for 150 lpi.

Bleed: 3 mm; safe margin 5 mm.

Trapping: 0.1–0.25 mm offset; 0.3–0.5 mm flexo.

Overprint: black text overprints; rich black knocks out.

Imposition: sheetwork, cut-and-stack, step-and-repeat.

PDF/X: X-4 transparency; X-1a flattened.

TAC: 300–330% coated; 260–300% uncoated.

Preflight: fonts, images, colours, bleed, overprint.

Offset: pH 4.8–5.5, conductivity 800–1200 µS/cm.

Packing: 0.10–0.15 mm squeeze.

Screen: mesh, stencil, squeegee 60–80 Shore A.

Flexo: anilox volume, 60° blade, 50–70 Shore A.

Digital: fuser, calibration per substrate.

QC: register ±0.1 mm; ΔE tolerance.

Make-ready: plate, ink, register, density.

Drying: oxidation, heatset, UV, water-based.

Grammage × area = weight per sheet.

Grain: fold parallel; affects strength.

Conditioning: 20–23 °C, 45–55% RH.

Coated vs uncoated: gloss, absorption.

Inks: oxidative, heatset, UV, water-based, plastisol.

Plates: thermal, violet, processless.

Blankets: compressible, conventional.

Adhesives: EVA, PUR, starch, cold glue.

Guillotine: clamp 30–60 bar; knife 21–24°.

Folding: buckle up to 16 pp; score ≥200 g/m².

Binding: saddle 8–64 pp; perfect for thicker.

Laminating: BOPP 15–30 µm; corona treatment.

Die-cutting: rule 23.8 mm; crease 23.2 mm.

Packaging: FEFCO styles; crease matches board.

Foil/emboss: temperature, dwell, pressure.

QC: fold cracking, squareness, trim, delamination.

Lab*: L 0–100; a green/red; b blue/yellow.

ΔE: 76, 94, 2000; tolerance ≤2–3.

Models: RGB, CMYK, spot; rendering intent.

Density: SID, TVI 12–20%, grey balance.

Proofing: contract proof measured; soft proof calibrated.

Metamerism: D50 vs D65.

Gamut: check profile; choose intent.

SPC: track ΔE and density.

Guards: interlocked; emergency stops; lockout/tagout.

Chemicals: SDS, GHS, ventilation, PPE.

Solvents: exposure limits; monitor VOC.

IPA: reduce; store safely.

Waste: segregate; hierarchy.

Ink/toner: hazardous waste; recycle cartridges.

Noise/dust: protection; extraction.

Fire: cabinets; extinguishers; drills.

Cost = materials + labour + machine + overheads + waste + margin.

Machine hour rate = annual cost ÷ productive hours.

Waste: 2–5% offset; 5–10% digital.

Scheduling: forward/backward; CPM; Gantt.

Capacity: speed × hours × utilisation.

Inventory: reorder point; FIFO.

Layout: flow; separate zones.

KPI: OEE; waste %; on-time; rework.

ISO 9001: QMS; procedures; audits.

ISO 12647: process control targets.

Job ticket: specification; approval.

Approval: signed proof is reference.

Documentation: SOPs; calibration; maintenance.

Traceability: batch numbers.

Complaints: root cause; CAPA.

Confidentiality: GDPR; customer data.