Conducting a Web Inkjet Substrate Trial
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Bill Verplank, Transactional Market Manager for Rollsource, the paper converting division of Unisource Worldwide, details recommended best practices, tips and tools for conducting a successful inkjet trial. Originally presented at the 2014 Inkjet Summit in Ponte Vedra Beach, Florida, Verplank explains why taking extra care to properly conduct an inkjet substrate trial will save time and money overall.
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Conducting a Web Inkjet Substrate Trial
- 1. Conducting a Web Inkjet Substrate Trial Best Practices
- 2. Why are paper trials important to you, the printer? Content provided in conjunction with Schilling Inkjet Consulting 2
- 3. Why are paper trials important to you, the printer? Inkjet-treated papers reduce ink usage - reduced cost of consumables Improved color outcomes – pre- print application converting to processed color inkjet Improved overall workflow performance leading to better throughput/ productivity Content provided in conjunction with Schilling Inkjet Consulting 3
- 4. What happens in a typical paper trial? …the first paper to work, wins! Content provided in conjunction with Schilling Inkjet Consulting 4
- 5. Paper trial challenges Non-scripted trial with no clear pre-trial or too general outcomes established. The paper industry’s eagerness to secure a foothold – throwing rolls at the opportunity Asset owners level of expertise – Is it OEM approved?, we’ll try just about anything or what I got works OK, can’t interrupt the work. Trial results typically yes/no with little useful information for stakeholders Early adopters experience trial fatigue as a result of poorly conducted trials Content provided in conjunction with Schilling Inkjet Consulting 5
- 6. Drivers for Substrate Change / Acceptance Improved overall workflow Performance leading to better throughput/productivity Improved color outcomes – pre-print application converting to processed color inkjet. Reduced cost of consumables IJ treated papers reduce ink usage and better color outcomes. Content provided in conjunction with Schilling Inkjet Consulting 6
- 7. Understanding those variables will ensure a successful paper trial, eliminating wasted time and consumable costs. The success of aqueous inkjet production depends on understanding your process and all the variables. Trial Preparation Content provided in conjunction with Schilling Inkjet Consulting 7
- 8. Focus on the Finished Product When preparing for an inkjet paper trial, think about the finished product first. What is the end product? • direct mail, transactional, trans promo, book, marketing, newspaper Finishing needs? • trim, score, binding, fold, inserting Expected color and print quality? Color match to other devices? Content provided in conjunction with Schilling Inkjet Consulting 8
- 9. Identify Print Coverage Content provided in conjunction with Schilling Inkjet Consulting 9
- 10. Identify Your Ink Know the colorant of your ink Pigment Dye Understand the ink composition Aqueous = water Understand the impact it has with various paper surfaces Content provided in conjunction with Schilling Inkjet Consulting 10
- 11. Paper Choices Based on print quality (PQ) or price ($) PQ and $ affect each other Acceptable PQ= $ uncoated Better PQ= $$ inkjet treated High PQ= $$$ Inkjet Treated Content provided in conjunction with Schilling Inkjet Consulting 11
- 12. Paper Choices Based on TIC (total ink coverage) TIC and paper surface affect print quality Ink dives faster into $ than $$ and $$$ papers $ papers require more ink to “build up” colorant on the surface than $$ and $$$. Also cockle and mottle issues Content provided in conjunction with Schilling Inkjet Consulting 12
- 13. Paper Choices Affect Image Quality Flat or low image definition Washed out or dirty color Color shift print to print Side to side color differences Print mottle Show thru Small text legibility 4 to 6pt Dot gain, lower image detail Color gamut, reproducible colors Content provided in conjunction with Schilling Inkjet Consulting 13
- 14. Trial Preparation Content provided in conjunction with Schilling Inkjet Consulting 14
- 15. Trial Preparation Prepare items needed previous to trial Schedule time with production Graphic files to be ran Check if paper profiles are needed Stage paper 24-48 hours before run Content provided in conjunction with Schilling Inkjet Consulting 15
- 16. Trial Preparation Prepare a trial outline for printer and paper supplier Files, coverage, paper specs, TAPPI roll info, profile name, run speeds, heat settings and print quality expectations Content provided in conjunction with Schilling Inkjet Consulting 16
- 17. Trial Preparation Pre-trial meeting with group Engage all workflow stakeholders Asses in-house equipment competency Set Print Expectations Content provided in conjunction with Schilling Inkjet Consulting 17
- 18. Trial Preparation Create job folder for all samples and documentation Content provided in conjunction with Schilling Inkjet Consulting 18
- 19. Paper Conditions Content provided in conjunction with Schilling Inkjet Consulting 19
- 20. Paper Conditions Verify paper width and core size Content provided in conjunction with Schilling Inkjet Consulting 20
- 21. Paper Conditions Paper check at the dock No telescoping or crushed cores No paper wrinkles or baggy rolls Content provided in conjunction with Schilling Inkjet Consulting 21
- 22. Paper Conditions Acclimate paper to print environment Min 24 to 48 before printing Content provided in conjunction with Schilling Inkjet Consulting 22
- 23. Paper Conditions Retain TAPPI paper label Content provided in conjunction with Schilling Inkjet Consulting 23
- 24. Time Scheduling Content provided in conjunction with Schilling Inkjet Consulting 24
- 25. Time Scheduling Scheduling time based on trial needs Est. 2-3 hours for one test roll Add 45 -1 hour for additional rolls 2-3 hours for each new paper spec addition for custom profile creation If customer is present, add 45 min to each additional test roll Content provided in conjunction with Schilling Inkjet Consulting 25
- 26. Time Scheduling Review prints 2-3 hrs after entire trial Allows print settle time-color and paper Content provided in conjunction with Schilling Inkjet Consulting 26
- 27. Our diverse product portfolio allows us to offer the best substrates for your unique workflow and color expectations. Stocking programs and JIT service in all major markets In business for more than 20 years 6 converting centers and 8 distribution centers Slitting and rewinding EDI and Vendor-Managed Inventory Comprehensive sample center Content provided in conjunction with Schilling Inkjet Consulting 27
- 28. Rollsource digital portfolio Compatible roll-feed products for all major OEM printing engines and pre/post processing equipment, including: Content provided in conjunction with Schilling Inkjet Consulting 28
- 29. Web Inkjet Test Sheet Content provided in conjunction with Schilling Inkjet Consulting 29 Download our Web Inkjet Test Sheet
- 30. Rollsource service network GP Paper Mill GP Warehouse Rollsource Regional Converting Center Rollsource/Appleton Regional Distribution Center Rollsource National Converting & Distribution Center Content provided in conjunction with Schilling Inkjet Consulting 30
- 31. Unisource locations GP Paper Mill GP Warehouse Rollsource Regional Converting Center Rollsource/Appleton Regional Distribution Center Rollsource National Converting & Distribution Center Content provided in conjunction with Schilling Inkjet Consulting 31
- 32. For more information, please contact: Bill Verplank Rollsource | Transactional Market Manager 900 N. Arlington Heights Road, Suite 190, Itasca, IL 60143 (616) 443 5674 bill.verplank@unisourceworldwide.com www.unisourceworldwide.com www.rollsource.com Content provided in conjunction with Schilling Inkjet Consulting twitter.com/Unisource_UWW linkedin.com/company/unisource-worldwide-inc
Editor's Notes
- Asset owners may perceive a new substrate as providing too small a change to justify trial and subsequent optimization . Optimization with some IJ print engines and post processing equipment require hours of non productive work. Trials are typically slapping a roll on the print engine, running it on an existing profile, whether matched to the trialed substrate or not, with the machine not optimized to the substrate. What have we really accomplished.
- Asset owners may perceive a new substrate as providing too small a change to justify trial and subsequent optimization . Optimization with some IJ print engines and post processing equipment require hours of non productive work. Trials are typically slapping a roll on the print engine, running it on an existing profile, whether matched to the trialed substrate or not, with the machine not optimized to the substrate. What have we really accomplished.
- Overall workflow – its important that all stakeholders participate to achieve these goals – Print Engine OEM, Unwind, Post Process OEMs, Inserter/Mail OEM. Share mini case study – Production IJ life on the streets – RevSpring and Great Lakes Loans – remove these company references when making PP available to attendees. Color Outcomes are typically subjective and reduced ink usage is hard to measure in most cases. Or improved workflow versus other print options make the ink cost mute.
- What is the end product and how will it need to be positioned within the roll to reduce paper waste. A important factor to understand before ordering paper roll width. How will it be converted. What machine will it need to go onto for finishing. Important to know before ordering paper weight All paper trials should include various finishing processes to ensure paper structure and ink saturation is suited for finishing needs. Paper weights should be made on end product needs and finishing characteristics. What is the expected color and print equability. Paper surface choices (uncoated, inkjet treated or inkjet coated) should be based on color and print quality needs If finished piece will be a combination of different devices, color expectations, color profiles and paper requirements need to be reviewed. Important for determining the proper paper weight, surface color and type as well as reproducible color gamut.
- How the piece is designed will impact production, print quality, drying, paper surface, paper weight and finishing What market the piece is designed to, will effect paper surface and weight, color and print quality requirements Having low, medium and high coverage test prints will help assess the right paper and print quality requirements for current and future jobs. Designing a “fingerprint” image containing pictures “flesh tones and facial detail” small text, line weights, pms colors and vignettes will help customers and designers, design to the “machine and paper” and not to their monitor assuring expectations are realistic to the finished product. Print many print combinations on various surface and paper weights so designers can understand the impact paper has print quality with aqueous inkjet. The quality of the file to be printed can have a strong impact on the trial outcome. A file used for other print technologies can not be assumed to work with all platforms. Printing these items on various uncoated, inkjet treated and inkjet coated in various weights will create an actual visual expectations Building a library of test results will help with future assesments.
- Aqueous Pigment and Dye ink react differently to paper surfaces. Aqueous inks use 90 to 95% water as the colorants carrier. Dye colorant when added to water creates a complete “mixture” or “solution”. Pigment ink colorant is a “flake” within the water which tries to attach itself to the paper fiber on the surface These inks also react differently to papers which are spec’ed the same, but from different mills Paper surfaces will react differently to aqueous inkjet inks as they hold slightly different chemistry in their ink composition Inks will absorb, spread, dry and look different depending on papers structure and surface Inks are changing and improving , with the overall goal to have production IJ match traditional Offset. Epson ink has been around for 17 years, both Ricoh and Canon are rolling out new improved inks. HP rolled out an improvement in 2012/13. Do not assume that the Print engine you buy today will not accomidate a new better ink in the furture. Improved inks are striving for substrate neutrality.
- How the ink reacts, absorbs and dries with in the paper structure will affect overall print and image quality Red line on the gamut image = Inkjet coated Green line on the gamut image = Inkjet treated Blue line on the gamut image = Uncoated free sheet I feel comfortable with this slide but will not dig deeper with regards to technical aspects of color gamut and ICC color profiles, but any paper provider should be able to provide resources to assist with these issues.
- Scheduling appropriate time needed with production seems easy, but too many times production interrupts the flow of the trial and creates longer trial times, redo’s and inconsistent trial data – these factors can lead to the asset owner simply slapping a roll on the press and hoping for the best outcome. It is also leads to the first paper that works wins. Staging paper ensures paper is conditioned to environment. Like any material, print quality is effected by substrate temperature and humidity Trial outline is incredibly important, as it keeps everyone organized and on track. But most important, it keeps the data organized so image and print quality comparisons on various papers can be assessed accurately at the trial and for future reference. Pre meeting to discuss what the customers print quality needs are. This ensures time is not wasted on papers which do not provide the quality needs outlined. Too many times papers are chosen based on price, but do not provide the required color and print quality needed by the customer. An achieved job folder of the trial is critical for future print quality reference and comparison. This is your benchmark of the paper and print settings to refer to if there is a future print quality difference or issue. It is easier to track problems if you know what you printed, as well as how you printed it.
- Order paper width which can accommodate each of the test prints needed and will correctly process for and required finishing testing – core size is a big issue with me and most paper companies. If you are planning on using more than one substrate, please work with 3” cores the most common core size in the paper industry. Checking paper quality and roll before printing will help eliminate printing or post finishing issues Telescoping, crushed cores, wrinkles or baggy rolls will cause machine and finishing issues. Guaranteed! – The highest percentage of affecting the overall quality of the roll is transportation. Rolls are meant to be hauled from the mill on their side in full truckloads. Trial rolls shipped one or two at a time are subject to excessive handling that leads to damage. Banded rolls in rolling position are subject to even more stress when shipped alone, single pallet. Relate great lakes loan story. Paper color effects the color matching and color quality. Check Lab color on each side of the paper Side to side paper color differences effect color matching from one side of the paper to the other Paper, like any material will perform and print differently based on temperature. Always acclimate the paper to production conditions. Keeping paper temperature variance low will ensure run to run color and expected print quality consistent TAPPI label contains vital information about that exact roll within the manufacturing run. If you see issues with the roll, the mill can trace the issues back to manufacturing. This helps paper mills and printers work better if there are paper issues and or returns. Tappi roll label should always be retained and archived with the printed samples and results
- It is so important to complete a trial outline previous to scheduling or attempting a roll trial Trial should be conducted based on the outline to ensure proper time is expected and production is not delayed Additional needs and rolls added day of trial should be scheduled for a different trial date, or trial outline and scheduling is reviewed with production. This happens so many times things are added at the last minute and production is delayed or trial is rushed and results are not accurate. Accurate trial results ensure correct paper type, surface and weight produce expected print quality as well as provide seamless production and finishing Scheduling should be based on activities needed as well as any production or customer distractions. Aqueous inkjet inks will continue dry within the paper over a few hours. Depending on the paper type, formation, surface and porosity, color can change up to 4-12 dE