Key Terms in KLD of Label.

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In this blog, we are going to learn about key terms in Key Line Drawing of Labels.

KLD?

It refers to the structural design and dimensions of a label. It includes important information such as cut lines, Perforation lines, NVZ area, Barcode area, and guidelines for essential graphic element placement.

It is very useful for designers and manufacturers to ensure accurate and consistent production.

In the above figure, I mentioned some of the key terms.

1. Length.
2. Width.
3. Corner Radius.
4. Perforation line.
5. Safe area.
6. Safe area margin.
7. NVZ Area.
8. Barcode Area.

The above-listed terms are discussed below in brief.

Length: 

It indicates the Around size of the label. It helps the graphic designer to know on which plate cylinder job is going to fit properly as well and it also helps in the job planning.

Width: 

It indicates the Across size of the label. It helps the job planner to find the paper width for the job and also helps the designer in imposition layout preparation.

Corner Radius:  

It is basically a rounded corner given on the label that allows easy release of matrix material from the printed web after die cutting. It is denoted by R.

Perforation line: 

It is generally indicated by the dotted line in the KLD. The structure of perforation helps the die-makers to prepare dies. 

Safe area: 

It is an area in the KLD in which all the graphic elements are going to be placed by the graphic designer to create artwork.

Safe area margin: 

It is a margin between the die line, perforation line, and safe area to protect the graphic elements from trimming off or tearing off.

NVZ Area (No Varnish Zone):

It is an area indicated in the KLD with the dimension as shown in the above image. It gives information to the Prepress designer for the preparation of the Varnish plate.

Barcode Area:

It is an area indicated in the KLD with the dimension as shown in the above image. It gives the idea to the graphic designer about the size and place for barcode placement.

Hope you get some knowledge from this blog.

Note: I am trying to give you, my best. It might be some mistakes happen. Please comment if any suggestions.

What is trapping and How to do it in illustrator

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In this Blog, we are going to learn about Trapping in printing.

Introduction

There are various printing processes available to print on various substrates such as paper, plastic, metal, etc. 

In multicolor printing, There is a chance of misregistration happening while printing due to the movement of machine parts. To minimize the registration issue we need to prepare artwork accordingly at the prepress stage for image carrier generation.

There are some processes done on the artwork to minimize misregistration are Trapping & Pull back with the help of software.

Trapping? 

It may be defined as the technique used at the prepress stage to minimize misregistration during the printing of multicolor using the conventional printing process.

There are two types of trapping techniques: 

1. Spread.
2. Choke.

Spread: 

Extension of the color outside to overlap the adjacent color throughout the boundaries of the element. 

Choke: 

Contraction of the color inside by overlapping the adjacent color throughout the boundaries of the element. 

Now, 

Trapping is done manually by using the Appearance and Attribute panel of Adobe Illustrator.

For spread.

Steps are given below: 

1. Open Appearance panel and Attribute panel from window menu.
2. Select the target element.
3. Go to the Appearance panel.
4. Keep the stroke layer below the fill layer and give the appropriate stroke point size.
5. Stroke color is similar to targeted element color.
6. Open attribute panel check the overprint stroke.
7. To check trapping do separation preview.

* Stroke point size is according to the printing process.

For choke

Steps are given below: 

1. Open Appearance panel and Attribute panel from window menu.
2. Select the target element.
3. Go to the Appearance panel.
4. Duplicate the fill layer select the top layer and do negative offset path from fx option.
5. Select the below fill layer.
6. Open attribute panel check the overprint fill.
7. To check trapping do separation preview. 

* Offset path is according to the printing process.

Hope you get some knowledge from this blog.

Note: I am trying to give you my best. It might be some mistake happen. Please comment if any suggestions.

Costing of Image carrier of Flexography Printing Process.

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In this Blog, We are going to learn. 

How to calculate the cost of the Image carrier of the Flexography Printing Process.

Image Carrier?

In the flexographic printing process, A flexible sheet is used with having raised image area and a recessed non-image area. 

Which is generally made by using photopolymer (Thermoset material) to transfer the ink from the Anilox Roller to the substrate for image generation is known as an Image Carrier. 

                                   

Fig: Image Carrier.

Size of the Image carrier.

We can calculate the size of the image carrier by using the Repeat Length (Circumference) of the printing cylinder and the required paper size for a particular job. It is generally in Sq cm.

Fig: Size of Image Carrier.

For Example:

Let us consider 

Artwork size is 289 x 140 mm. It is perfectly set on the Repeat length of 292.1mm and the Paper size is 155 mm.

So, the size of the Image carrier = 292.1mm x 155 mm.

Cost of the Image carrier.

We can calculate the cost of the Image carrier using the formula written below:

Cost= {(Repeat Length + Trimming Allowance) (Paper Size + Trimming Allowance)} X Rate per Sqcm.

Note: Put all values in cm. 

*Trimming allowance =1 cm.

In the above example, the Repeat length is 292.1 mm (29.2 cm) and the Paper size is 155 mm (15.5cm)

So, the cost of the plate is 

= (29.2+1) (15.5+1) X 1.2 = Rs 597.96.

Here, the Rate per sq cm is Rs 1.2.

Or you may download the sheet given on below link: 

Download link.

You have to put the rate and size in mm in sheet to get the cost of image carrier.

Hope you get some knowledge from this blog.

Note : I am trying to give you my best. It might be some mistake happen. Please comment if any suggestions.

Distortion of Flexography Photopolymer Plate

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In this blog, we are going to learn about what is Distortion & How to calculate it theoretically.

First of all, What is the term distortion?

Distortion means deformation of original shape and size of an object when it is twisted, stretched, or wrapped.

In the case of the Flexography Photopolymer plate. when it is mounted over the plate cylinder, It changes their thickness as well as length in the mounting direction. 

We need to prepare the plate smaller in length from the circumference of the plate cylinder. So, it finally matches the length after being mounted on it known as the Distortion of the flexography photopolymer plate.  

Some defects arise due to improper distortion such as a distorted image. improper mounting.

Now, the Formula for the calculation of distortion of flexography Photopolymer plate.

Distortion constant = 

2 X 3.14 (Plate Thickness - Polyester Backing Thickness)

Soft part thickness =

Plate Thickness - Polyester Backing Thickness

Plate Size = 

Plate cylinder Teeth X 3.175 mm – Distortion Constant.

Note: Put all the values in mm.

Polyester Backing thickness.

• 0.127 mm for 1.7 mm plate Thickness.

• 0.178 mm for 1.14 mm plate Thickness.

For Example: 

Let us consider 

Cylinder Teeth is 92 T.

Plate Thickness is 1.14 mm. 

Polyester Backing Thickness is 0.178 mm.

Distortion Constant = 2 x 3.14 (1.14 - 0.178) mm.

                                = 6.041 mm

So, we need the Perfect Plate Size for 

92T (292.1 mm) is 6.041 mm smaller in length

ie ; 286.058 mm.

Note: After Preparation of Imposition layout select the whole layout and change the length 292.1 mm to 286.058 mm in Adobe illustrator, Then, Send to next process.

Hope you get some knowledge from this blog.

Note : I am trying to give you my best. It might be some mistake happen. Please comment if any suggestions.

How to calculate creasing matrix width for a job.

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To calculate the creasing matrix width for papers boards having different thickness , we have to follow the given formulae.

B=2C+D  

Where,

                B= Width of creasing matrix.

                C= Thickness of paperboard.

                D= Thickness of Creasing Rule.

Note:

1. All values should be in mm.

2. The values of thickness of creasing rule is given in point by the manufacturer sometime. Hence, we have to convert it into mm.

                    i.e. 1 pt = 0.35277mm

Hope you get some knowledge from this blog.

Note : I am trying to give you my best. It might be some mistake happen. Please comment if any suggestions.

Creasing Matrix for folding carton.

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In this blog, I am going to tell you about creasing matrix which is used in carton manufacturing industries.

First of all what is creasing Matrix ? 

It is a device used in manual or automatic die cutting machines for making perfect creases on paperboard for ease in folding.

Important parts of Creasing Matrix. 
There are some important  parts of creasing matrix are as follows:

1. Locator.
2. Matrix.
3. Chamfered Edge.
4. Self Adhesive.
5. Thin Film Base.
6. Finger Lift Release Paper.

1. Locator:- It is made-up of flexible plastic. It holds the matrix on the creasing rule. The locator is mounted over the creasing rule to hold the matrix. 
2. Matrix:- It is made-up of hard material. The creasing rule is comes to the groove of the matrix to crease the paper or board.
3. Chamfered Edge:- The edges of matrix are made slightly tapered to protect the matrix from unnecessarily come-out from the plate.
4. Self Adhesive:- It facilitates the matrix to stick on the plate.
5. Thin Film Base:- It holds the matrix together.
6. Finger Lift Release Paper:- It protects the adhesive of matrix to get damage. Before Sticking it on the plate, this paper is removed.

Thanks for your interest in reading my blog. Hope you gain some knowledge.

Note : I am trying to give you my best. It might be some mistake happen. Please comment if any suggestions.

Running length of label stock for job.

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In this blog, I am going to share a most important formulae used in label printing industry. 

I am using this formulae to know how much length of label stock required to print the given job.

The formulae is written as: 

Running Meters =    R.Length x Quantity

                                     ________________________

                                       No. Of ups x 1000

Where, 

1.) R. Length means the circumference of printing plate cylinder.

*It is generally given in Teeth.

For example:  92T

So, we have to convert in mm by multiply with 3.175mm

= 92 x 3.175mm = 292.1mm 

2.) No of ups means the no of around label into across label.

3.) Quantity = Total no of label required.

Sample question : 

Cylinder teeth : 92T

No of around label : 4

No of across label : 4

Quantity : 100000

Solution :

R.Length : 92 x 3.175mm = 292.1 mm

Running meter = 292.1 x 100000

                                ________________

                                    16 x 1000

                             = 1826 metre.

Hence, To print the 100000 label requires 1826 metre label stock.

Note : I am trying to give you my best. It might be some mistake happen. Please comment if any suggestions.

Calculation of Compression strength of corrugated fibre box.

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Today, we are going to know, How to calculate the compression strength of corrugated fibre box theoretically.

First of all, what is compression strength of corrugated fibre box?

It may be defined as the ability of box to withstand the amount of compressive force applied on it before going under deformation.

By the help of McKee formulae we can calculate the box compression.

BCT= 6 X ECT X √Z X √T

Where,

BCT = Box compression test in KgF.

ECT = Edge compression test in KgF/cm.

Z = Perimeter of box.

T = Thickness of board.

*ECT = 1.28 ( RCTL1+mRCTL2+RCTL2) 

The above formulae is for 3 ply. So you have to change RCT and m according to the no of ply.

where, m = Take up factor of flute.