The perfect print production process

As dedicated experts in print, we thought we'd give you our guide to the perfect print production job, from start to finish.

1. The quote process

Here is where you take a step back and look at the project as a whole. Provide your client with a figure based on hourly rates, resources used & time spent.

2. Graphic design

Following a brief from the client, the design team get their creative juices flowing. Before you even start the design, ensure that you select all the appropriate software for every stage of the design process. Next, the layout of the design should be appropriate and spaced out evenly (not cramped in the middle of the page or too close to the page borders. A few more things to keep in mind:

• You have approved fonts with full licenses.
• Suitable image resolution with full image rights.
• That have had approval from to client to send to print.

3. Sending to print

Correct file naming and storage. When storing design documents, it is important you save changes from the client as Version 1, Version 2, V3 etc. This way if your client changes their mind, you can then refer to a previous version of the design they were happy with.

File storage is the format in which you save the document, this could be pdf, svg, jpg, png, gif & many more. Always ensure you send to print in the most appropriate format.

File preparation – the final step before sending to print. This is for adding features such as bleed around the edges of the file or including crop marks.

4. Prepress

Once the print team have received the files from the design team, they have two initial tasks to complete. The first task is the pre-press checks. Although the design team should have done their own proofing before sending it, there is always a human error factor to proofing, so a second pair of eyes wouldn’t do any harm. The 3 most common errors to look out for are: typos (error in text), design errors, or preparation errors (missing crop marks, bleed etc.). The file must also be checked to ensure the files are indeed in the correct format and resolution, this is to make sure the print run is successful.



5. Creating a Proof

Once the graphics file passes the pre-press stage, it moves on to the second pre-press stage - creating a proof. A proof is a close representation of how the finished piece will appear when it is printed.

On many projects, such as business cards or postcards, a proof is often created as a PDF. Since a PDF is an electronic file, it can be emailed to the client for approval…which greatly speeds up the proofing process.

Also, if a print project involves finishing operations such as binding or folding - like that of a book or brochure - it is recommended that a physical proof be created. A physical proof will demonstrate how the piece will be constructed, where it will be folded, the order of the pages, etc.

In addition to avoiding any unforeseen errors, the purpose of the proof stage is to ensure that the client and printer are in complete agreement on the desired outcome.

6. Printing

The Printing Stage covers the transfer of an image to paper. Offset lithography is based upon two main principles:

That water and grease do not mix.

The ink is offset from a plate (positive image) to a rubber blanket (negative image) and then to the substrate (as a positive once again).

When a printing plate is made, the printing image is rendered grease-receptive and water-repellent, while the non-printing areas are rendered water-receptive and ink-repellent. On the press, the plate is mounted onto the plate cylinder which, as it rotates, comes in contact with rollers wet with water (or dampening solution) and rollers wet with ink. The dampening solution wets the non-printing areas and prevents the ink from penetrating these areas. The ink wets the image areas, which are transferred to the intermediate blanket cylinder. The paper picks up the image as it passes between the blanket cylinder and the impression cylinder.

While this process involves primarily one machine, there are many areas of concern.

To ensure high quality printing the printer must:

·     Match the ink colour specified

·     Control dot gain

·     Minimize paper movement

·     Minimize image distortion or noise such as dust & hickies.

·     Check that the pages back each other correctly.

·     Evaluate halftone quality and attempt to hold the highlight & shadow detail.

7. Finishing/ Post-press

These are the processes which occur once an item has been printed. This could include folding, binding, cutting, embossing, debossing, foiling, laminating, Spot UV, laser cutting or a wide range of other finishing activities.

Special finishes add a unique look and feel to documents. Gold or silver foiling adds a sparkle and exclusivity to documents. Lamination, a layer of protection or tactility to items and debossing or embossing, a satisfying and subtle raised or recessed surface. This is where a plain document can turn into something truly special. This is a process we call The Lami Touch and can be totally unique and/or personalised for each document being produced.