Professional Documents
Culture Documents
While the industry accounts for a significant portion of the nations' total volume of goods
and services, it also represents the largest conglomeration of small businesses in the
domestic manufacturing sector. Seventy nine percent of the plants in the industry
employ 19 people or less (PIA 1999 Report to Congress). Most firms in the industry
serve local or regional markets, though some printers and many publishers reach
national and international markets (USIO 1992).
While there are significant variations in the process, this etool attempts to simplify the
overall operation into three broad categories. First, pre-press will include everything
needed to develop an image from the idea stage to a plate that can be used in a
printing press. Second, the press stage will include both sheetfed and webfed processes
and will include all tasks from loading raw substrate (usually paper) into the press to
the finished product being removed from the press. Finally, finishing and binding will
include those processes used to further process the printed material into a finished
item.
Potential hazards and possible solutions for the following tasks are covered below.
Side-bar design
from simple manual to fully automated equipment
designs
maximum degree of automation, also with extremely
sticky filter cake
comparatively low structure weight
Plant design/engineering
Applications
Maintaining a clean environment, production of food and beverages, and development of
essential medicines require filters that separate solids from liquids. ANDRITZ offers filter
presses for a wide variety of applications and industries, ranging from treatment of wastewater
sludge and drinking water, the food and beverage industry, the chemical industry, pharmacy
and mining, to paper production. Applications include:
chemicals and pigments
metallurgical products and ores
minerals and inorganic products/mining
pasting
Have you ever received a financial statement in the mail, perhaps a short (8- to 16-
page) prospectus for a mutual fund, and noticed that it was not saddle stitched,
perfect bound, or bound in any other usual way? The nested pages just stuck
together and didn’t fall apart. This is called paste-binding, and for the
right commercial printing jobs it’s a wonderful way to save money and time.
The Usual Binding Methods
Usually, when you’re producing a short publication, you will saddle stitch the
printed product. That is, you will bind it with staples through the fold, and all the
pages will stay together. This is good for printed products up to about 80 or 96
pages (depending on the weight of the press sheet). In some cases (usually
magazines printed on relatively light text stock), you may even see saddle stitching
done on much longer printed products, although there’s always the possibility that
pages will fall out if you try to saddle stitch too long a print book, magazine, or
catalog. (Your printer can provide you with guidelines pertaining to his specific
binding equipment.)
Another way you might bind a short publication is to side stitch the printed product.
Like saddle stitching, this uses lengths of binding wire (that look like staples), but
these are inserted down through the pages rather than sideways through the fold.
When to Request Paste Binding
If your printed product fits the following requirements, consider the alternative of
paste binding instead:
printing
One of the most important functions in the printing process
is prepress production. This stage makes sure that all files are correctly
processed in preparation for printing. This includes converting to the
proper CMYK color model, finalizing the files, and creating plates for each
color of the job to be run on the press.
Offset lithography is one of the most common ways of creating printed
materials. A few of its common applications include: newspapers,
magazines, brochures, stationery, and books. Compared to other printing
methods, offset printing is best suited for economically producing large
volumes of high quality prints in a manner that requires little
maintenance.[7] Many modern offset presses use computer-to-plate systems
as opposed to the older computer-to-film work flows, which further
increases their quality.
Advantages of offset printing compared to other printing methods include:
consistent high image quality. Offset printing produces sharp and clean
images and type more easily than, for example, letterpress printing; this
is because the rubber blanket conforms to the texture of the printing
surface;
quick and easy production of printing plates;
longer printing plate life than on direct litho presses because there is no
direct contact between the plate and the printing surface. Properly
developed plates used with optimized inks and fountain solution may
achieve run lengths of more than a million impressions;
cost. Offset printing is the cheapest method for producing high quality
prints in commercial printing quantities;
ability to adjust the amount of ink on the fountain roller with screw keys.
Most commonly, a metal blade controls the amount of ink transferred
from the ink trough to the fountain roller. By adjusting the screws, the
operator alters the gap between the blade and the fountain roller,
increasing or decreasing the amount of ink applied to the roller in certain
areas. This consequently modifies the density of the colour in the
respective area of the image. On older machines one adjusts the screws
manually, but on modern machines the screw keys are operated
electronically by the printer controlling the machine, enabling a much
more precise result.[8]
Disadvantages of offset printing compared to other printing methods
include:
The most common kind of offset printing is derived from the photo offset
process, which involves using light-sensitive chemicals
andphotographic techniques to transfer images and type from original
materials to printing plates. In current use, original materials may be an
actual photographic print and typeset text. However, it is more common—
with the prevalence of computers and digital images—that the source
material exists only as data in a digital publishing system.
Offset printing process consists of several parts:
Final print
igital printing refers to methods of printing from a digital-based image
directly to a variety of media.[1] It usually refers to professional printing
where small-run jobs from desktop publishing and other digital sources
are printed using large-format and/or high-volume laser or inkjet printers.
Digital printing has a higher cost per page than more traditional offset
printing methods, but this price is usually offset by avoiding the cost of all
the technical steps required to make printing plates. It also allows for on-
demand printing, short turnaround time, and even a modification of the
image (variable data) used for each impression.[2] The savings in labor
and the ever-increasing capability of digital presses means that digital
printing is reaching the point where it can match or supersede offset
printing technology's ability to produce larger print runs of several
thousand sheets at a low price.[3]
Process
In many of the processes, the ink or toner does not permeate the
substrate, as does conventional ink, but forms a thin layer on the surface
that may be additionally adhered to the substrate by using a fuser fluid
with heat process (toner) or UV curing process (ink).
Digital printing methods of note[edit]
Fine art inkjet printing
Fine art digital inkjet printing is printing from a computer image file
directly to an inkjet printer as a final output. It evolved from digital
proofing technology from Kodak, 3M, and other major manufacturers,
with artists and other printers trying to adapt these dedicated prepress
proofing machines to fine-art printing. There was experimentation with
many of these types of printers, the most notable being the IRIS printer,
initially adapted to fine-art printing by programmer David Coons, and
adopted for fine-art work by Graham Nash at his Nash Editions printing
company in 1991.[4] Initially, these printers were limited to glossy papers,
but the IRIS Graphics printer allowed the use of a variety of papers that
included traditional and non-traditional media. The IRIS printer was the
standard for fine art digital printmaking for many years, and is still in use
today, but has been superseded by large-format printers from other
manufacturers such as Epson and HP that use fade-resistant, archival
inks (pigment-based, as well as newer solvent-based inks), and archival
substrates specifically designed for fine-art printing.[5][6]
Digital inkjet printing also allows for the output of digital art of all types as
finished pieces or as an element in a further art piece. Experimental
artists often add texture or other media to the surface of a final print, or
use it as part of a mixed-media work. Many terms for the process have
been used over the years, including "digigraph" and "giclée". Thousands
of print shops and digital printmakers now offer services to painters,
photographers, and digital artists around the world.
Digital laser exposure onto traditional photographic paper[edit]
folding
For magazines, books,… large press sheets need to be folded into
signatures. This involves a series of right-angle folds in which the sheet is
folded multiple times. Folding a sheet once makes four pages, two right-
angle folds make eight pages,…
Other types of work require parallel folds in which two or more folds which
are oriented in the same direction are made in a sheet. This is typically
done for leaflets or brochures. Some common types of folds are:
There are two common types of folding machines: the knife folder, also
known as a right-angle folder, and the buckle folder. In general knife folders
are used for heavier stocks, while buckle folders are used for lighter paper
types.
Three different folders are used in modern print shops. They range in
complexity from the bone folder to the buckle folder. Bone folders have
been used for centuries and are made of either bone or plastic. These
folders are simple shaped pieces of bone or plastic that are passed over
the fold to form a sharp crease. Today, they continue to be used, but only
for small, very high quality jobs.
Knife folders use a thin knife to force the paper between two rollers that are
counter-rotating. This forces the paper to be folded at the point where the
knife contacts it. A fold gauge and a moveable side bar are used to position
the paper in the machine before the knife forces the paper between the
rollers. The rollers have knurled surfaces that grip the paper and crease it.
The paper then passes out of the folder and on to a gathering station.
Several paper paths, knives and roller sets can be stacked to create
several folds on the same sheet as it passes from one folding station to
another.
Buckle folders differ from knife folders in that the sheet is made to buckle
and pass between the two rotating rollers of its own accord. In a buckle
folder, drive rollers cause the sheet to pass between a set of closely
spaced folding plates. When the sheet comes in contact with the sheet
gauge, the drive rollers continue to drive the paper causing it to buckle over
and then pass between the folding rollers.
COVER
Self-covers are made from the same
material as the body of the printed
product. Newspapers are the most
common example of a printed product
that uses self-covers. Soft covers are
made from paper or paper fiber material
that is somewhat heavier or more
substantial than the paper used for the
body of the publication. This type of cover
provides only slight protection for the
contents. Unlike self-cover, soft covers
almost never contain part of the message
or text of the publication. A typical example of the soft cover is found on
paper-back books. These covers are usually cut flush with the inside pages
and attached to the signatures by glue, though they can also be sewn in
place.
Casebound covers are the rigid covers generally associated with high-
quality bound books. This method of covering is considerably more
complicated than any of the other methods. Signatures are trimmed by a
three-knife trimming machine to produce three different lengths of
signature. This forms a rounded front (open) edge to give the finished book
an attractive appearance and provides a back edge shape that is
compatible with that of the cover. A backing is applied by clamping the
book in place and splaying or mushrooming out the fastened edges of the
signatures. This makes the rounding operation permanent and produces a
ridge for the casebound cover.
Gauze and strips of paper are then glued to the back edge in a process
called lining-up. The gauze is known as "crash" and the paper strips are
called "backing paper." These parts are eventually glued to the case for
improved strength and stability. Headbands are applied to the head and tail
of the book for decorative purposes. The case is made of two pieces of
thick board, called binder's board, that is glued to the covering cloth or
leather. The covering material can be printed either before or after gluing
by hot-stamping or screen methods. The final step in case binding consists
of applying end sheets to attach the case to the body of the book.
Cutting
The machine typically used for cutting large web-type
substrates into individual pages or sheets is called a
guillotine cutter or "paper cutter". These machines are
built in many sizes, capacities, and configurations. In
general, however, the cutter consists of a flat bed or
table that holds the stack of paper to be cut. At the rear of the cutter the
stack of paper rests against the fence or back guide which is adjustable.
The fence allows the operator to accurately position the paper for the
specified cut. The side guides or walls of the cutter are at exact right angles
to the bed. A clamp is lowered into contact with the top of the paper stack
to hold the stack in place while it is cut. The cutting blade itself is normally
powered by an electric engine operating a hydraulic pump. However,
manual lever cutters are also still in use.
To assist the operator in handling large reams of paper which can weigh as
much as 200 pounds, some tables are designed to blow air through small
openings in the bed of the table. The air lifts the stack of paper slightly
providing a near frictionless surface on which to move the paper stack.
The cutter operator uses a cutting layout to guide the cutting operation.
Typically, the layout is one sheet from the printing job that has been ruled
to show the location and order of the cuts to be made. Though cutting is
generally considered a postpress operation, most lithographic and gravure
web presses have integrated cutters as well as equipment to perform
related operations such as slicing and perforating.
Binding
Adhesive binding, also known as padding, is the simplest form of binding. It
is used for note pads and paperback books, among other products. In the
adhesive binding process, a pile of paper is clamped securely together in a
press. A liquid glue is then applied with a brush to the binding edge. The
glue most commonly used in binding is a water-soluble latex that becomes
impervious to water when it dries.
For note pads, the glue used is flexible and will easily release an individual
sheet of paper when the sheet is pulled away from the binding. Adhesive
bindings are also used for paperback books, but these bindings must be
strong enough to prevent pages from pulling out during normal use. For
paperback book binding, a hot-melt glue with much greater adhesive
strength than a water-soluble latex is applied. A piece of gauze-like
material is inserted into the glue to provide added strength.
Looseleaf bindings generally allow for the removal and addition of pages.
This type of binding includes the well known three-ring binder.
In saddle binding one or more signatures are fastened along their folded
edge of the unit. The term saddle binding comes from an open signature's
resemblance to an inverted riding saddle. Saddle binding is used
extensively for news magazines where wire stitches are placed in the fold
of the signatures. Most saddle stitching is performed automatically in-line
during the postpress operations. Large manually operated staplers are
used for small printing jobs.
Another saddle binding process called Smythe sewing is a center sewing
process. It is considered to be the highest quality fastening method used
today and will produce a book that will lie almost flat.
References
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2014.
2. Jump up^ Stewart, Alexander A. (1912). The Printer's Dictionary of
Technical Terms. Boston, Mass.: North End Union School of Printing.
pp. vi–ix.
3. Jump up^ Kafka, Francis (1972). Linoleum Block Printing. Courier
Corporation. p. 71.
4. ^ Jump up to:a b c Eisenstein, Elizabeth (2012). The Printing
Revolution in Early Modern Europe (2nd ed.). Cambridge University
Press. ISBN 978-1107632752.
5. Jump up^ "Over 600 Years of Printing
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fm
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13. Jump up^ http://www.meridianpress.co.uk/blog/45/thoughts-
on-traditional-letterpress-printing
14. Jump up^ Bednar, J.b. (2010). "Making an Impression" (p. 52-
58). Businesswest.
15. Jump up^ "Boxcar Press File Preparation". Boxcar Press.
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16. Jump up^ Letterpress Commons. "Maltriculated
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18. Jump up^ Waters, Alice. 30 Recipes Suitable for Framing.
Index