09.30.14
The Printing Plant, a label and flexible packaging converter in Cincinnati, OH, USA, is a family owned business that has been in operation since 1979. A narrow web flexo and digital printer, The Printing Plant has grown considerably over the years, adding experienced staff and the most up-to-date converting technology.
The company's move to G7 qualification from IDEAlliance was customer driven and started with The Printing Plant’s digital press. While they already had Color Certification, more of their customers were searching for and demanding G7-qualfied printers. The company decided that becoming G7-qualified for both their digital and flexo presses was an important part of the strategy for maintaining its demanding customers and for future growth.
Beginning the G7 Qualification Process
The Printing Plant began the G7 qualification process working with an individual on its digital press. After the qualification of the digital press was complete, they started the process for their 10-color flexo press. Unfortunately, the company soon realized that the individual they were working with did not have the expertise required to manage the process on flexo presses, so the process stopped.
At this point, the Printing Plant then turned to their plate house for help. They recommended The Printing Plant contact All Printing Resource’s (APR) Catherine Haynes, a G7 Expert. They said she was more than qualified to manage the process that would lead them to formal qualification as a G7 Master Printer by IDEAlliance.
Shortly after the referral, John Hayden, production project manager for The Printing Plant met Haynes, who was a speaker at an event sponsored by Clemson University. After a lengthy discussion that confirmed Catherine had the expertise to do the job, John retained Catherine to facilitate the implementation of the G7 process and submit documentation and samples to IDEAlliance on the company’s behalf. Haynes was very prompt and detail oriented. She quickly started the process by supplying the team with an agenda and helped with building the test form and planning the schedule for the press runs.
The entire G7 qualification process entails:
• Defining the goal
• Running a gray-balance target
• Measuring and analyzing the target
• Applying the curves to the file
• Running the gray-balanced plates
• Profiling the process
Haynes noted that the calibration has a two-fold benefit. First, it brings a process into a known state – one defined by standards that direct us to a commonly agreed upon state of order. Second, it also helps extend the life of the process, bringing it back to a known state of order – to the specs.
The first phase of the calibration process required linear press runs to benchmark where The Printing Plant was and then the development of necessary curve adjustments. The second phase involved rerunning the test form with the adjusted curves to validate that the adjustments worked. There was a third and final run to confirm the results. Both, the company's Jetrion digital press and Roto 10 flexo press were qualified. The entire process took three days to complete.
The Printing Plant was already measuring density and dot gain before the G7 qualification began, and Haynes helped the team understand the difference between measuring gray balance versus watching color. Hayden worked with Haynes during the G7 qualification, helping measure all the samples, watching and learning and then sharing that information with his team. Now whether he is on site or not, the team can make sure that the process is followed correctly.
Getting a “buy-in” from their press operators was not a big issue. “We had spectrophotometers and densitometers,” Hayden explains, “and they were already doing most of the measurements that are required. No new tools or training were needed, and we made their jobs easier.”
Now that the G7 qualification has been successfully completed, The Printing Plant is educated about the process and able to continue applying the gray-balancing process for themselves. Future G7 Master qualifications by IDEAlliance though will require another submission process through a G7 Expert. At that time The Printing Plant will be calling on Catherine.
“Catherine knew what she was talking about,” says Hayden. “She was professional, easy to work with, and explained everything. We understand what is needed and can easily maintain the process. We’re ready for the next customer requiring G7 qualification.”
The company's move to G7 qualification from IDEAlliance was customer driven and started with The Printing Plant’s digital press. While they already had Color Certification, more of their customers were searching for and demanding G7-qualfied printers. The company decided that becoming G7-qualified for both their digital and flexo presses was an important part of the strategy for maintaining its demanding customers and for future growth.
Beginning the G7 Qualification Process
The Printing Plant began the G7 qualification process working with an individual on its digital press. After the qualification of the digital press was complete, they started the process for their 10-color flexo press. Unfortunately, the company soon realized that the individual they were working with did not have the expertise required to manage the process on flexo presses, so the process stopped.
At this point, the Printing Plant then turned to their plate house for help. They recommended The Printing Plant contact All Printing Resource’s (APR) Catherine Haynes, a G7 Expert. They said she was more than qualified to manage the process that would lead them to formal qualification as a G7 Master Printer by IDEAlliance.
Shortly after the referral, John Hayden, production project manager for The Printing Plant met Haynes, who was a speaker at an event sponsored by Clemson University. After a lengthy discussion that confirmed Catherine had the expertise to do the job, John retained Catherine to facilitate the implementation of the G7 process and submit documentation and samples to IDEAlliance on the company’s behalf. Haynes was very prompt and detail oriented. She quickly started the process by supplying the team with an agenda and helped with building the test form and planning the schedule for the press runs.
The entire G7 qualification process entails:
• Defining the goal
• Running a gray-balance target
• Measuring and analyzing the target
• Applying the curves to the file
• Running the gray-balanced plates
• Profiling the process
Haynes noted that the calibration has a two-fold benefit. First, it brings a process into a known state – one defined by standards that direct us to a commonly agreed upon state of order. Second, it also helps extend the life of the process, bringing it back to a known state of order – to the specs.
The first phase of the calibration process required linear press runs to benchmark where The Printing Plant was and then the development of necessary curve adjustments. The second phase involved rerunning the test form with the adjusted curves to validate that the adjustments worked. There was a third and final run to confirm the results. Both, the company's Jetrion digital press and Roto 10 flexo press were qualified. The entire process took three days to complete.
The Printing Plant was already measuring density and dot gain before the G7 qualification began, and Haynes helped the team understand the difference between measuring gray balance versus watching color. Hayden worked with Haynes during the G7 qualification, helping measure all the samples, watching and learning and then sharing that information with his team. Now whether he is on site or not, the team can make sure that the process is followed correctly.
Getting a “buy-in” from their press operators was not a big issue. “We had spectrophotometers and densitometers,” Hayden explains, “and they were already doing most of the measurements that are required. No new tools or training were needed, and we made their jobs easier.”
Now that the G7 qualification has been successfully completed, The Printing Plant is educated about the process and able to continue applying the gray-balancing process for themselves. Future G7 Master qualifications by IDEAlliance though will require another submission process through a G7 Expert. At that time The Printing Plant will be calling on Catherine.
“Catherine knew what she was talking about,” says Hayden. “She was professional, easy to work with, and explained everything. We understand what is needed and can easily maintain the process. We’re ready for the next customer requiring G7 qualification.”