Multiple printing design of the hottest corrugated

2022-08-08
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Multiple printing design of corrugated boxes

in the past, the main function of corrugated boxes was as transportation packaging, and its surface printing was also very simple. The reasons are as follows: first of all, carton manufacturers and users do not pay attention to the packaging design of corrugated cartons, and only use cartons as a tool to protect and contain products; Secondly, the surface flatness of corrugated boxes is relatively poor, which makes it difficult to print exquisite patterns; Thirdly, the previous printing plates were hand engraved plates, which could not reproduce the fine lines and points at all. Of course, there are also insufficient printing units and other reasons, which limit the rapid development of carton printing

in recent years, with the rapid development of economy and the increasing exchanges with foreign countries, people have increasingly realized the importance of packaging and decoration, especially the influx of international supermarkets such as Wal Mart and Carrefour and the increasing number of domestic supermarkets, which have changed people's traditional shopping habits and made the sales function of corrugated boxes increasingly prominent, Users began to pay more and more attention to cartons, the outermost packaging that shows products and the company's image. At the same time, the widespread application of flexo (photosensitive resin plate) and the rise of flexo prepress technology have also given strong support to carton printing

in the field of packaging design, the previous color packaging or exquisite packaging design was mostly achieved by offset printing and gravure printing. Offset printing and gravure printing are mature printing methods, and there are still many printing adaptability that need designers' attention in packaging design. As a new printing method, flexo printing requires designers to further understand the characteristics of flexo printing in order to truly reproduce designers' packaging design. In the prepress design of corrugated box direct flexo printing, designers must pay attention to the following points

first, the number of colors that clearly express creativity

the vast world is colorful. Especially the designer's eyes are good at discovering beautiful colors and organizing them organically to create all kinds of works that are elegant, bold, warm, or have strong visual impact. As a packaging design, the ultimate goal is to achieve their own creative effects after printing, and to achieve industrial production. Therefore, for the packaging design of corrugated box direct flexo printing, in terms of color application, we must first understand that our creativity is realized on several color printing machines, and make it clear that our creativity is expressed through several colors. The number of domestic corrugated box flexographic printing machine units is generally 2, 3, 4, 6. Before confirming the use of several colors, on the one hand, we should consider the number of color groups of the printing machine, on the other hand, we must consider whether to use white ink and varnish from the process, so as to finally determine the number of colors that can be used to express creativity

of course, on the premise of fully expressing the design creativity, the number of printing colors should be reduced as much as possible, which is beneficial to the printing operation, quality control and cost control in mass production

in addition, many manufacturers hope to use as many spot colors as possible to achieve the color unity of each batch of products and play a certain anti-counterfeiting role. Therefore, in addition to the traditional cmyk4 color, more spot color inks are used in the design of its packaging. However, in practice, due to the limitations of the printing press, the manuscript that needs to be printed on the four-color machine cannot be displayed in any case with four colors during color separation. Finally, we have to communicate with the designer to merge the similar colors into one color or change the designer's work

because flexo printing is transferred through the roller, the number of roller lines determines the amount of ink transferred and the fineness of printing. Generally, the high-line texturing roller should be used for eye adjustment to make the dot printing clear; The field version uses a low thread count roller to achieve color saturation. When there are both eye tone image and field in a color, and it is visually prominent, this color is generally divided into eye tone plate and field plate to make plates respectively during color separation, so as to facilitate printing operations. Therefore, when considering the overall color number in the design process, do not ignore the characteristic of color separation in flexo printing

in addition, this situation is often encountered in practice, that is, many corrugated box printing machines are three color machines, which cannot achieve normal four-color printing. Therefore, in the process of colorization of corrugated box watermark, three colors are often used to reproduce four-color manuscripts. When using tricolor overprint to produce black, we need to consider the following two actual situations:

(1) ink color deviation makes tricolor overprint produce non-standard black

(2) three color overprint will make the ink layer too thick and affect the printing quality and effect

in view of the above two situations, when dealing with packaging products printed by three color machine, designers should understand the situation of ink. Some printing inks used in printing plants are biased, so it is necessary to properly consider reducing the color intensity of the biased colors when processing, and some manuscripts do not necessarily need to remove the black version. For example, the green version can be removed from reproducing food, and the red version can be removed from reproducing trees, so as to maintain the style and level of the original to the greatest extent. If the problem of printing color number is considered in the design, the above difficulties will not be encountered before mass production. For example, when dealing with the design of Tsingtao beer cartons, we took into account that it should be realized by three-color printing machine, so we successfully realized the color printing process of corrugated carton watermark and promoted it in the market

second, pay attention to the use of levels

due to different tastes of designers and different characteristics of products, there are differences in the style of packaging design. Some pursue simplicity and lightness, while others pursue richness. However, if its design works are realized through flexographic printing, the application of levels in its design must attract the attention of designers

because the flexible version is relief, and the material has high elasticity and is easy to deform, the point increases seriously after compression. In the process of plate making, 1% or 2% of the small points are easy to be lost during plate washing, and cannot be well reproduced in the printing process. 3% of the points will expand to about 10% after printing, and it is impossible to achieve the effect of gradual change from 100% to 0% or very soft layers, Therefore, flexographic products can show relatively few levels of highlights and dark tones, and products with better printing can only reproduce 8% - 10% of the highlights. Therefore, the point smaller than 8% in the design cannot be shown in the actual printing. For example, the use of gradient color, if the point gradient to 0%, there will be obvious boundaries or impressions in the small points or absolutely places, which will affect the image of the package. Although each manufacturer has its own way to overcome or solve this problem, in any case, flexographic printing cannot be comparable to offset printing. Only by taking this feature of flexo into consideration when designing, can your design be realized after printing

for another example, if the edge of the image is diluted to the extreme, the problems mentioned above will also occur, which requires designers to consider avoiding such problems when designing packaging

in addition, as mentioned earlier, the number of roller lines used for ink transfer in flexo printing is different from that of the eye tone version and the field version. Large areas of the field are connected with local gradients, so printing is very difficult. Especially for manuscripts with darker field colors, the eye tone part is taken care of, and the field printing is not real or the color is light; After taking care of the field, the eye adjustment part is pasted, which is dirty. Although it can sometimes be solved by selecting a moderate number of lines and reducing the number of lines in the eye adjustment part, it is inconsistent with the designer's original design intention anyway

it is worth mentioning that in packaging design, gold and silver ink are often used to enrich the effect of packaging design and improve the quality of packaging. When using gold and silver inks, if the pattern contains eye tones, it is best to leave more space at the highlight and dark tones, and the highlight should be more than 20%, because this kind of ink printing point is easy to paste

third, consider printing registration

like offset printing and gravure printing, flexographic printing also involves overprinting. In flexographic packaging design, on the one hand, we should pursue the exquisite pattern, on the other hand, we should also consider the printing difficulty. For example, for small words and patterns, if you want to express them through overprint, because the overprint accuracy is difficult to ensure, it is bound to increase the scrap rate or make the printed patterns unsightly. This problem is usually solved by trapping. The trapping of corrugated boxes is usually 0.5 ~ 1mm, sometimes it may be slightly smaller for different printing machines. If it is difficult to print words and patterns under such a big trap, it must be adjusted accordingly. Especially for the overprint of complementary colors, there will be obvious black edges at the junction of the two colors, which will affect the aesthetic feeling of the packaging. Relatively speaking, dark and light overprint will be much better. In addition, a group of words or color blocks are overprinted by multiple units, which also increases the printing difficulty. Since most of the flexo printing machines used in China are driven by gears, the regular color block or line arrangement of one deep one light two or more colors in the packaging design will also cause difficulties for printing

the relief pattern on the flexograph is brushed off the unexposed part by the plate washing solution and brush. If the test piece needs to be formed by the second experiment, the flexograph has requirements for the size of the smallest words and the thinnest lines. For corrugated box printing, we suggest that the thinnest line should not be less than 0.5mm. If it is an isolated line, it should also be widened appropriately. As for text, it is best to refer to the above data for the stroke thickness. Because the stroke structures of boldface and Song typeface are different, it is not easy to uniformly set the minimum font size. Pay special attention when using "Song Dynasty" font, because the contrast between the thickness of horizontal and vertical lines is too large

in the use of bar code, because the flexo plate is easy to deform under pressure during the printing process, and the plate is pasted flat on the round cylinder, it will also deform, so we must pay attention to the bar code processing. For different printing machines and bar code sizes, each bar code must be reduced in advance before plate making, so as to ensure that it can be detected after printing. Of course, this reduction is completed by the manufacturers who speed up the upgrading of plastic granulator technology in plate making. Here, designers should be reminded to pay attention to the direction and size of the bar code. The size of the bar code should refer to the standard, and the direction of the bar code should be consistent with the printing direction as far as possible

fourth, pay attention to the typesetting effect of packaging design

in packaging design, general designers only pay attention to the finished product effect and plane effect of packaging, and pay little attention to the typesetting effect of packaging. Printing is a mass production process, which needs to arrange the single pictures of the packaging according to the width of the printing machine and the circumference of the plate roller. Therefore, the typesetting effect must be considered in the design. Especially when a single pattern needs to be arranged repeatedly, the color of the intersection position should be consistent or the design of the connected pattern should be continuous, so as to avoid the local pattern on one package appearing in isolation on the adjacent package on the layout due to the die-cutting deviation after printing, resulting in the unsightly package of the finished product. Such typesetting should be avoided as far as possible in the design

the above-mentioned problems involving typesetting are all small-size packaging. In fact, many corrugated box packaging are large-size packaging, such as refrigerators, monitors, etc. when designing these large packaging, we must consider the limitations of film output and plate making size. At present, the maximum plate making size of domestic flexo cannot exceed 2000mm × 1320mm, film output at 1100mm × Most of them are within 800mm. When designing large-size packaging, we should consider these process characteristics and exceed these sizes

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