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3. Disc variants
1. Printing Process
1.1. General
When printing a disc the company of Sony DADC distinguishes between screen- and offset printing, whereby both are
dependent on design and data build-up and each have their advantages and disadvantages.
Solid coated PANTONE colours, which we mix directly, are generally used for screen printing. This procedure is generally
used for simple designs or areas. (Fig 1)
Sony DADC also offers the picture print (4C Screen print- CMYK) in screen printing. This print is mainly used for
simple pictures that barely show gradients and have more than 6 colours (therefore nor possible in PANTONE).
(Fig 2)
The offset print allows Sony to print low tone values and all kinds of pictures. (See also Fig 3)
- All Sony screen print machines are equipped with 6 print heads.
This means a max. of 6 colours can be printed.
For example: White + 4 colours + varnish
White + 5 colours....
- The PANTONE colours do not cover completely 100%, which means if two colours are printed over each other
slight colour changes can occur. This is why fine components and texts must be left out of Pantone colours.
Exceptions:
- Black and Silver (P877C) are covering
- Duplex-pictures in which a light and dark PANTONE colour are used
- The screen print PANTONE colours always have a glossy surface - that is why PANTONE references of PANTONE
UNCOATED cannot be accepted.
- PANTONE possesses a maximum screen width of 34 lines/cm (85lpi). These pantone colours are not suitable
for screening, because the screen points with such a rough screen are clearly visible. The screen points would
blur with a higher screen. The tone value should at least reach 10% since the screen points would otherwise
be too small for the screen and therefore not be printable.
- If large areas are printed in screen, the tone value should not have over 90% (also counts for KNRC colours), or
else the area could smear up, which leads to an uneven, cloudy result. For that reason a alternative PANTONE
colour (printed in 100%) is recommended for large screen areas.
- Lines must have a width of at least 0.10mm (positive) and 0.15pt (negative) to achieve an optimal result.
- The letter size of the text must at least amount to 4pt (positive) and 5pt (negative). (Fig 4)
A a B b C c D d Ee Ff Gg
A a B b C c D d E e Ff Gg
Hh Ii Jj Kk Ll Mm Nn Oo Hh Ii Jj Kk Ll Mm Nn Oo
Pp Qq Rr Ss Tt Uu Vv Pp Qq Rr S s Tt Uu Vv
- PANTONE colours are normally always printed on white. If this is not desirable the client has to be informed,
that the colour changes and does not match the PANTONE spectrum. (Fig 5)
Fig 5
- Gradients are not recommended in PANTONE, because this leads to edges that influence the result.
(Fig 6 and 7)
Fig 6 Fig 7
Fig 8 Fig 9
In this range the blue P801C is the colour that has the least fluorescent effect.
Fig 10
Fig 11
Fig 12
1.3. Offset
- Offset printing is only possible for the colours Cyan, Magenta, Yellow and Black. Because these colours are
purchased in addition, no special colour mixing is possible.
- The offset print has the possibility, aside from the 4 CMYK colours, to print an extra PANTONE colour on the
first and on the last place.
For example: a white pre- print and at the end another effect with diverse varnishes or also a PANTONE colour.
In doing so the order is not variable (SD / CMYK / SD)!
- Furthermore it is important, that a certain fitting inaccuracy due to the different print procedures can occur,
when combining screen print and offset print.
- The offset print uses a lower full tone density. This effect is noticeable if one prints 100% black. If larger areas
are printed, problems develop because the black seems gray and staining and irregularities appear in the area.
This effect can be corrected by depositing the black with the other CMYK- colours. Ideal are the values 60%
Cyan, 40% Magenta, 40% Yellow und 100% Black! (Fig 13)
- The offset print is not suitable for the printing of large areas. In print a bar or staining could form. If a strong
bar is formed, someone should try and find another solution, because in such cases the clear varnish would
just enhance this effect. Here for example a PANTONE print would be recommended.
Fig 13
- The offset colours have a slightly matt surface. If the client does not wish this, one can improve the result with
clear varnish.
- A white pre-print is always recommended, unless the client wishes a metallic effect. Thereby one has to
consider that the colours change as well. (Fig 14 and 15)
- If a label is printed without a white base coat or with the separate white base, one has to pay attention that
the disc in the area between Spec. B and A has a barcode ring. (Fig 16 and 17) The visibility of the bar code
ring minimized with the white base.
This must be authorized by the client.
Fig 16 Fig 17
- The shining through of the disc silver changes the colour and does not correspond anymore with the PANTONE
colour guide. (See also1.2.1. Pantone colours)
As the different disc types (CD-R, DVD-R, AUDIO,..) have different shades of colour, the appearance of the
white base colour is changed by the reflexion characteristic.
3. Disc variants
Aside from the different product types at Sony DADC, there are also different disc types:
- 12 cm Disc
This disc is printable with all specifications. The max. external diameter is 117mm.
- 8 cm Disc
It is printable for all specifications. The max. external diameter is 77mm.
- Dualdisc
The disc is printed on both sides and has a DVD (Side A- max. external diameter 43.5mm) and a CD (Side B-max.
external diameter 33.5mm).
- DVD 10
The disc is printed on both sides like the dual disc, but has 2 DVD sides (mostly PAL and NTSC). The standard
DVD10-H/A-STAND (External diameter 43.2mm) and DVD10-H/B-STAND (External diameter 35mm) or the
standard DVD10 RING/SPEC.G (max. external diameter 38.5mm) is used for the white pre- print.
- VinylCD
The Vinyl CD can be produced in the most various colours (Black, gold,..). The design can have an external
diameter of 54mm or 62mm. To achieve the vinyl effect, rings out of clear varnish (with a colour vinyl disc) or
Marabu Black (with black vinyl) are printed on the end. Vinyl discs can only be printed offset.
- Blu-Ray
A special white is used for the white pre-print (Colour description = BD- White). The Blu-Ray Disc can only be
printed in offset. Special varnishes and a separate white base are not possible. The Blu- Ray logo should only
have one colour or feature gray shades.
- Super Audio
The conventional white full base colour 117mm is used for the base.
Since Black is a covering colour, it can be printed over the PANTONE colours. This is very helpful for printing if there
is a main text or a fine design in the design. When over printing there is the so called register impreciseness avoided.
Black should if possible be set to overprint, unless this is not possible for reasons of data transfer or it does not work
with the design. (This can also be used for P877C!)
4.2. When to use Marabu Black (#34) and when to use KNRC 65 (#54)
If a design predominantly consists of an area and the screened design is very simple, it is possible to expose the films
in #34, because with Marabu Black the area print turns out nicer. If the screen design, however, predominates or the
design is very fine or rather has different gradients, it must be printed in KNRC 65 with #54 to achieve an acceptable
result.
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