First 4.0 Paving the way for flexographic excellence potx

Trang 2

Why Is FIRST SO IMPORTANT! ® FIRST is the most important

document the FFTA has ever produced

® Provides guidance and leadership to the industry

® Enables printers to be consistent with

Trang 3

= >: = Ớ) = a FIRST 4.0 The Mission of FIRST

FIRST seeks to understand customers’ graphic requirements for reproduction and translate those aesthetic requirements into specifications for each phase of the flexographic printing process including: customers, designers, prepress providers, raw material & equipment suppliers, and printers

The intention of FIRST is to provide all participants in the flexographic reproduction process with a common set of

guidelines, tutorials, and data that can be used as communication and production tools

FIRST Objectives

FIRST is @ set of specifications, not standards When followed, these specifications facilitate producing a predictable, consistent result It is the responsibility of the customer to determine where, when, and how these specifications are implemented This does not imply that a printer's capabilites cannot exceed FIRST specifications, or that the printer is limited to these specifications as a maximum quality level The process and specifications supported in FIRST intend:

* To outline key flexographic procedures and guidelines to be used from the beginning of the process to the end,

including the implementation, design, prepress, and print processes

® To improve quality and consistency through improved communication and measurement procedures

*® Toreduce cycle time and minimize rework through improved process control methodology

* Tocontrol production costs through streamlined raw materials and process improvement methodology * To enable consumer product companies to obtain optimal flexographic print quality, which equals or exceeds

offset lithography and gravure printing

* To grow the overall flexographic printing industry through increased market share of an expanding market

Historical Perspective of FIRST

Prior to FIRST, many consumer product companies were creating individual package reproduction specifications The generation of too many individualized specifications can become overwhelming to an industry — resulting in manufacturing inefficiencies and confusion In pursuit of a more universal approach, the FTA membership partnered with leading consumer product companies to create a universal set of flexographic specifications

The resulting premier edition of FIRST (debuting in 1997) and subsequent editions consisted of specifications and tolerances representing the realistic capabilities of 70% of the industry Data was derived from three years of industry input, three industrywide surveys, and statistically controlled designed experiments FIRST 4.0 includes technical updates to maintain relevancy with the everevolving technology, as well as significant subject expansion designed to more fully encompass the entire flexographic process and various industry segments With hundreds of industry experts, from around the world, contributing to the technical content over the past decade, FIRST has become the

Trang 5

= bị = Ớ) = a

The Mission of FIRST

FIRST seeks to understand customers’ graphic

requirements for reproduction and translate those aesthetic requirements into specifications for each phase of the flexographic printing process

including: customers, designers, prepress

providers, raw material & equipment suppliers, and printers

The intention of FIRST is to provide all participants in the flexographic reproduction process with a

common set of guidelines, tutorials, and data that can be used as communication and production

tools Ay

Trang 6

FIRST Objectives

¢ To outline key flexographic procedures and

guidelines to be used from the beginning of the

process to the end, « including the

implementation, design, prepress, and print processes

¢ To improve quality and consistency through improved communication and measurement procedures

¢ To reduce cycle time and minimize rework

Trang 7

FIRST Objectives

¢ Tocontrol production costs through streamlined raw materials and process improvement

methodology

¢ To enable consumer product companies to

obtain optimal flexographic print quality, which

equals or exceeds ¢ offset lithography and

gravure printing

¢ To grow the overall flexographic printing

Trang 8

= bị = Ớ) = a A Historical Perspective

Prior to FIRST, many consumer product companies were creating individual package reproduction

specifications The generation of too many individualized specifications can become overwhelming to an industry — resulting in

Trang 12

IMPLEMENTATION —

Communication is the foundation of FIRST Using agreed upon terminology and a defined workflow, FIRST seeks to minimize miscommunication and promote the manufacturing of consistent, conforming flexographic materials The role of the customer is crucial to the communxation and implementation of specifications The customer determines the requirements and establishes the objectives for each job Printers and suppliers help the customer achieve their quality and cost containment goals within the given timeframe Each member of the supply chain must utilize process control methodologies if the final product is going to conform to the quality and cost goals established by the customer The customer and suppliers must have a detailed plan and well-defined workflow to efficiently produce the printed material The FIRST Packaging Development Workflow diagram (pages 2 — 3) provides an overview and clarifies the role of each party within the production workflow The diagram facilitates an understanding of the workflow, for what and when each party is responsible, and a resolution path if the product fails to meet quality standards at any stage of the workflow Each supplier must implement spacifications, including process control of vanables, to ensure the final product is compliant vath the predetermined job specifications

CGATS TR 011-2002 (Graphic Technology — Package Development Workflow —- Design Concept Through Approved Production File) describes a model for the package development process beginning with the identification of a project through preperation of an approved production file It is intended for use as a reference in the creation of workflow procedures for specific organizations or products CGATS TR 012-2003 (Graphic Technology Color Reproduction and Frocess Contro! for Package Printing) outlines the steps necessary to understand and objectively define the color and tone reproduction capabilities of a specific printing process The steps identified in CGATS TR-012 provide information required in the package development workflow (CGATS TR-011) The Committee for Graphic Arts Technologies Standards

(CGATS) technical reports 011 and 012 can be obtained from NPES (The Association for Suppliers of Printing, Publishing

Trang 13

The Foundation of FIRST

Communication

Trang 15

= bị = Ớ) = a Consumer Product Company (CPC) ¢ Key Responsibilities: — Design Brief

Trang 17

Designer ¢ Key Responsibilities: — Design Strategy — Final Digital Production Art created in adherence to specifications

— QC all deliverables — providing process

Trang 18

= bị = Ớ) = a Prepress ¢ Key Responsibilities:

— Color Separations created to specifications — Film/File Assembly created to specifications — Contract/Color Proofing created to

Specifications

— QC all deliverables — providing process

control run targets & verification documentation

— Platemaking (when applicable) conforming

to specifications

Trang 19

= >: = Ớ) = a Press ¢ Key Responsibilities:

— Press Optimization, Fingerprint & Characterization, Process Control &

Improvement — as defined in FIRST 4.0 Print

sections 19.0 — 19.5 and in CGATS TR-012

— Platemaking (when applicable) conforming

to specifications

— Producing the package to specifications

— QC finished product providing process

control & verification documentation

Ay

Trang 20

Package/Product Development Team

Consumer Product Compan Designer 2 (CPC)

+ Key Responsibilities: * Key Responsibilities:

~ Design Brief ~ Design Strategy

~ Package Structure (primary and ~ Final Digital Production Art created in secondary) adherence to specifications

— QC all deliverables — providing process control run targets & verification documentation within the design ~ Consumer Research Strategy —~ Promotion Strate Press Prepress + Key Responsibilities:

Color Separations created to specifications ~ Film/File Assembly created to specifications

Contract/Color Proofing created to specifications

QC all deliverabies — providing process P Í control run targets & verification

re p re Ss S } documentation

— Platemaking (when applicable) conforming to specifications

* Key Responsibilities:

Press Optimization, Fingerprint & Characterization, Process Control & Improvement — as defined in FIRST 4.0 Print sections 19.0 — 19.5 and in CGATS TR-012 ~ Platemaking (when applicable) conforming

to specifications

Producing the package to specifications QC finished product providing process

Trang 21

= bị = Ớ) = a Package/Product Development Project Team

The primary role of each organization in the package development process can be summarized as:

«Consumer Product Company: is the customer

¢Graphic Designer: creates the original design file

‘Prepress Provider: evaluates and applies the color characterization data to art file, provides contract proofs and makes image carriers (plates, cylinders, etc)

Trang 22

Pre-production Team Meeting

The meeting agenda includes these items for discussion: «Package Design Objectives

‘Design Review

«Design Specifications

‘Package Sizes — Similarities & Differences

«Discussion of best production techniques for the design «Number of Colors Needed

«Electronic Assembly

«Contract Proofing Requirements

Trang 23

= >: = Ớ) = a Pre-production Meeting - Mechanical

Decisions needed at this time include the number of colors on the job, the method of printing, and the designation of the printing

substrate Topics for discussion at this meeting should include: *Separation—Printer Concerns

‘Specific Trapping/Film Assembly Issues

«Process Control Targets (placement of run and control targets) «Press Characterization Requirements and Layout (if necessary) ¢-Finishing Requirements — review template: glue zones, cuts, scores, non-print areas, eye-mark location, die-lines, etc

-Timetable

Trang 26

Reality Check

¢ All press teams are familiarized and adhere to the results of the

optimization, fingerprint and

Trang 27

Communication

* Optimization: The first step requires the -:

printer to analyze the printing process to :Z 150 Ipi 175 lpi ie

determine preferred operating parameters Preferred operating

parameters strike a balance between print quality, print stability (ability to maintain

throughout the run and across runs), and efficiency of operations = > = Ớ) = a ¢ Components:

— Anilox Rolls, Mounting Tapes, Inks, Plate

Types, Substrates, Press Settings, Etc

Trang 28

Internal Communication

Preferred Operating Parameters

Trang 29

Internal Communication Photopolymer Plate Card Card Cylinder Size: Job Name: Web Size: Gear Size: Date Returned Date In: Date Out: Comments

Standard Operating Conditions (SOC)

Trang 30

External Communication

Trang 31

External Communication

Pre-production Team Meeting Pre-production Meeting - Mechanical

The meeting agenda includes these items for discussion: Decisions needed at this time include the number of colors on the job, the

Package Design Objectives method of printing, and the designation of the printing substrate Topics for Design Review discussion at this meeting should include:

Design Specifications Separation—Printer Concerns Package Sizes — Similarities & Differences Specific Trapping/Film Assembly Issues

Discussion of best production techniques for the design Process Control Targets (placement of run and control targets)

Number of Colors Needed Electronic Assembly Contract Proofing Requirements Method to review, revise and approve color Timetable

On-Press Approvals Image Carrier/Plates

Trang 33

FIRST 4.0 DESIGN INTRODUCTION 2.0 2.1 Overview

FIRST 4.0 is created to facilitate ication among all participants involved in the design tion and printing of flexographic materials The designer is responsible for creating « graphic design that achieves the maerketing objectives of the Consumer Product Company (CPC) and that can be successfully reproduced on press The Design Section is intended to assist the designer in understanding the flexographic print considerations necessary to create ible designs The better the designer understands the flexographic process, the easier it will be to create A prirmary

reproduc

sesthetcally pleasing designs while optimizing production efficiency and reducing the tirne-to-market objective of the Design Section is to provide guidance on how to create electronic files that will enhance quality and speed of manufacturing while minimizing cost This must be accornplished while allowing the designer to maintain creative control of the project This can be best accornplished when everyone in the supply chain has s clear understanding of the requirements of flexography and these requirements ere addressed during the design phase of development Because designers and production artists often have overlapping responsibilites, the information in this section applies to both parties

Depending on the methods and practices of the companies involved and the complexity and frequency of the work among thern, FIRST recormmends establishing ground rules and procedures for designing products before actual production

begins This is a necessary step when services to the flexographic industry because of the complexity of

the graphics, print issues, and converting equipment consideratons A dialogue regarding design and production

considerations should bei nen among the pr duction tearm ( product compsny, prepress proveier,

and printer) FIRST p: to fa ‘i the proj flow through the d ign and ta ing pr

2.2 Responsibility

As packaging graphics continue to increase in cornplexity and production timelines continue to compress, the clear assignment of responsibilities | is necessary to ensure a quality printed product in a timely manner The assignment of responsibilities requires planning and laboration among all involved perties

* Consumer Product Company (CPC): Uttirnately, the customer defines expectations and therefore, must drive the collaboration process The customer determines the effort expended to reach satisfaction The CPC must facilitate communication between the supply chain parties: designer, prepress provider and printer ¢ Designer / Production Design: The designer must work with both the prepress prowider and the printer to

understand the capability of the printing/converting process being utilized Based upon the print capability, the designer must provide @ design concept that will enable the printer to meet the expectations of the custorner (CPC) The earlier in the design developrnent process the prepress prowder and printer are involved, the better able the tearm is to determine specific capabilites and ensure the final product meets the customer's design objectives Additionally, the designer is responsible for-

Establishing a basic color scheme and color palette before final files are sent to production

-

* Checking all copy for spelling and keming

© Treating common elements and logos consistently in the layout

« Building all copy and vector-based elements in accordance with the specifications of the print prowider

¢ Prepress Provider: The prepress provider must work with the printer to understand the capability of the printing’converting process being utilized The prepress provider supplies the designer with accurate and tmely information regarding print capabilities at the beginning of the design phase to facilitate the creation of a printable design Based upon the print capability, the prepress provider produces appropriate filme/files/plates that will enable the printer to meet the expectations of the customer (CPC) They must document the controls

FLEXOGRAPHIC IMAGE REPRODUCTION SPECIFICATIONS & TOLERANCES

Founding Sponsors

Ron&Katherine Harper

Trang 34

Attributes of Flexo

The use of spot colors, specialty inks, and a wide variety of substrates are just a few of the choices available with

flexography Designers must be informed about the advantages of the flexographic printing process in order to make use of them during the design process The designer must communicate with the print provider to understand their capabilities and how they

Trang 35

Design Section

¢ The designer is responsible for creating a graphic design that achieves the marketing

objectives of the Consumer Product Company (CPC) and that can be successfully reproduced on press

¢ Aprimary objective of the Design Section Is to provide guidance on how to create electronic files that will enhance quality and speed of

manufacturing while minimizing cost

¢ FIRST recommends establishing ground rules and procedures for designing products before

Trang 37

Prepress

410.1 Overview

FIRST 4.0 is | created to $tacditate communication sags all Perticipants involved in the design preperation and printing of fi The p for transforming the product design into files/filrns/plates , ready to be flexographically for on press The ability of the prepress provider to apply his

knowledges of the printing and converting process to the current design directly impacts the quality of the printed piece, the efficiency of the press oy and the overall tirme-to-market of the new product The Prepress Section is intended to 1g the fi “grap hic print Yy to produce quality graphic assist the prepress Pp

files in today’s environment ck CGïricsssseds từưnefrarnes

10.2 ee

eee graphics to in complex

= P ibslities is r y to @ quality printed product in a timely manner The sesignement of re and collab ion among all involved parties A more detailed review of the Package

1 Poss=e ae the roles of and responsibilities of each perty are provided in Implementation Section 1.3

The Package Development Process

Consumer Product Company: Ultimately, the customer defines expectations and therefore must drive the

process The customer determines the effort expended to reach satisfaction The CPC must

-

collaboration

facilitate communications between the supply chain parties: designer, prepress provider and printer * Designer: The designer must work with both the prepress provider and the printer to understand the capability

process being utilized Based on the print capability, the designer must provide s design concept that will enable the printer to meet the expectations of the customer (CPC) The earlier ¡ in the of the printing/converting design development process the prepress provider and printer are involved, the better the team is able to determine specific capabilities and ensure the final product meets the custorner’s design objectives *° Prepress Provider: The prepress provider must work with the printer to understand the capability of the printing/

converting process being utilized In order to create a printable design, the prepress provider is responsible for providing the designer with accurate and timely information regarding print capabilities at the beginning of the design phase Based on the print capability, the prepress provider produces appropriate filrme/files/pletes that will enable the printer to meet the expectations of the customer (CPC) They must document the controls thet ensure the consistency and accuracy of the supplied media (films/files/plates) Additionally, the prepress provider is responsible for producing a contract proof calibrated to predict the printed result The prepress provider must provide the printer the ability to objectively confirm the accuracy of the prepress work and the printing process This can be accomplished through the use of agreed-upon control targets

© Printer: The printer is responsible for consistently reproducing the graphic design to the satisfaction of the customer (CPC) They must utilize and docurment the process controls necessary to ensure that accuracy and consistency are achieved They must work with the other parties and suppliers to define the capability of the

printing process At the beginning of the design phase, the printer is responsible for providing the designer with se Thang: informaton regarding process capabilities This information facilitates the creation of 8 printable de = >: = Ớ) = a

FLEXOGRAPHIC IMAGE REPRODUCTION SPECIFICATIONS & TOLERANCES

S82 TEST Founding Sponsors

Ron&Katherine Harper

Trang 38

= >: = Ớ) = a Prepress Section

The prepress provider is responsible for

transforming the product design into production files/films/plates ready to be flexographically

Trang 39

= bị = Ớ) = a Key Attributes 11.0 - Electronic/Digital Files 12.0 - Joo Assembly 13.0 - Color Separations

14.0 - Process Color Calibration 15.0 - Final Output Specifications 16.0 - Color Proofs

17.0 — Printing Plates

Trang 40

FIRST

4.0

18.0 PRINT INTRODUCTION

participerts involved in the design, preperation and printing of eloprment Process and the roles and responsibi

1s The ability of

Overview

12.1

FIRST 4.0 is created to facilitate cormmunication

flaxographic materials A rnore detailed review of the Package

Kha nhường th tung cuoi coi tanolt ly 1.3, The Package Development Process The printer is responsible for reproducing the design and i th h the Vand to

pri setae 1Ï wal toni ninh nh nh Di n6 on iotsoal ru ae ainda: the efficiency of the ptr dg besa an dnn an wih cacat tar gtr inden rent npc anythin Section of FIRST 4.0 assists the printer in g the fi grap 1G Print consistency,

bility; thereby ing pr

Ỉ

Pp and

comtinue to compress, the clear assignment of TS ee eee The assignment of responsibilities

LỄ +2 Responsibility

ee in cornp y¥ and p ibil it a quality prirte

Consumer Product Company: Ultimately, the customer defines expectations and therefore, must drive the

to reach satisfaction The Consumer

requires ciara and toi 0ntlion among all involved

determines the effort expended

i ion b \ the supply chain parties: designer, prepress

-

collaboration process The

Product Cornpany (CPC) must facilit comrr provider and printer

re men Hcy arr apn ante oneal cance danse yale sosognedntsete phan

b utilized Based upon the print capability, the d

the customer (CPC) ke=geerverced

-

of the printing/converting process being

@ design concept thet will enable the printer to meet the expectations of

the design development process the prepress provider and printer are involved, the better able the team is to determine specific capabilities and ensure the final product meets the customers design objectives HƠI CƠN NNNN VN OỢẠN NA

ible for providing the designer with accurate fs bsg

@ printable design Based upon the print capability, the prepress provider prod

thet will enable the printer to meet the expectations of the customer (CPC) They must document the controis thet ensure the consistency and accuracy of the supplied media Filna/files/plates) The prepress provider is ea producing a contract proof calibrated to asccurately predict the p d result Additi , they must provide the printer the ability to objectively confirm the accuracy of the prepress work and the printing

process This can be accomplished through the use of agreed-upon control targets \ © Printer: The printer is responsble for consistently reproducing the graphic design to the satisfaction of the Ỉ

customer (CPC) The printer must utilize and document the process controls necessary to ensure that accuracy \ and consistency are achieved They must work with the other parties and suppliers to define the capability of the ị printing process The printer is responsible for providing the designer with accurate and tirmely information regarding \ process capabilities st the beginning of the design phase to facilitate the creation of a printable design \

Ink Supplier: The ink supplier is responsible for consistently providing ink that meets the functional and color

requirements of the job They must utilize and document the process controls necessary to ensure the acouracy and consistency of the ink They must work with the printer to understand the capability of the printing process and the requirerments of the particular job

FLEXOGRAPHIC IMAGE REPRODUCTION SPECIFICATIONS & TOLERANCES

#'* T€ST Founding Sponsors

Ron&Katherine Harper