In the printing industry, one of the most critical factors that professionals closely monitor is overprinting accuracy. This is because a significant portion of production waste often stems from misregistration issues. While flexo printing machine manufacturers have designed machines with precision in mind, and automatic monitoring systems help maintain consistency, the operator's skill and experience still play a crucial role in achieving accurate overprinting.
Designing the original artwork with overprinting in mind can significantly simplify the printing process and reduce waste. For example, using reverse white text or creating a hollowed-out space between two colors to form a white outline can make registration easier. Alternatively, slightly thickening the edges of overlapping color areas can help create a more defined trap, especially for fine prints.
When dealing with high-precision jobs, trapping technology becomes essential. The amount of trapping required depends on several factors, including the press’s accuracy, the paper quality, and the operator’s expertise. Implementing trapping during the prepress stage can save time and improve print quality.
Trapping can be easily done using digital software. If you don’t have access to computers, you can use ready-made dichroic films along with a trapping modifier device. By entering the desired trapping value, the machine will automatically generate the necessary trap film. In the absence of such tools, a transparent spacer can be placed between the color separation film and the copy film, and then exposed using a single-point light source. This method can also produce acceptable results for basic trapping needs.
Overall, understanding and applying proper overprinting techniques not only improves print quality but also reduces material waste and production costs. It’s always beneficial to plan ahead during the design phase to ensure smoother and more efficient printing processes.
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