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The CHAMPIONS promote a multi media publishing concept. Most guides on this site are PDFs that can be download and printed on demand. Some are available in printed versions, please contact us for availability and price., if these are not indicated on the brief descriptions below.

Roll To Web Processing

Published by Web Offset Champion Group

Roll to web processing is not only the start of the printing process but also paper is its largest expense (50-70% of total operating costs) making it essential to minimise waste from all causes. IFRA states that "often roll preparation produces such surprisingly high and unnecessary amount of waste that the productivity of the entire printing press can be affected. Any miss-splice, following a careless preparation, or any web break due to an inaccurate check of the roll will cause a long production interruption with the corresponding consequences. The successful preparation of the splice greatly depends on the skill and experience of the staff."

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Web Break Prevention & Diagnosis

Published by Web Offset Champion Group

Web breaksand mis-splices are usually caused by the simultaneous occurrence of different disturbances. They are often triggered by a minor change in one factor. A survey of 50 international printers found that web breaks are a significant problem for 95 % of them; and what is an important web break cause at one printer may be relatively unimportant to another. This variability is due to different technologies, papers, materials and environments. Data on web break causes are also variable making extrapolation of cause and effect more difficult. This guide provides a diagnosis aid to 140 web break and mis-splice causes and identifies best practices to avoid and minimise them where possible.

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Related FREE poster to download : Paper and Roll Defect Classifications

How To Avoid Surprises When Changing Paper Grades

Published by Web Offset Champion Group

Different papers have variable process requirements that impact pre-press, printing, finishing and total cost. This guide focuses on three grades of paper (LWC, SC, INP) to show what changes can be expected and best practices to improve performance. The economic models and research results indicate the importance of different variables. The single most important factor affecting total cost and quality is the matching of prepress profiles to paper grade and press. Effective use of industry reference targets are critical to the integration of digital workflows, creating ICC profiles and the effective use of CTP. Other key influences are maintenance, press settings, environmental conditions and the selection of the right combination of consumables for each press.

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Productivity Maintenance

Published by Web Offset Champion Group

Maintenance has a major impact on printing productivity but it does not always attract the attention it deserves. The biggest causes of lost time and increased costs as equipment failures, set-up and adjustment, idling and minor stoppages, reduced speeds, defects in the process and start-up and reduced yields. Disturbances either consume production time or increase waste. They fall into three types : sudden events that can stop the press, cumulative, where the printer can choose when to stop the press, and those that reduce speed or quality. There is an intrinsic relationship between productivity, reliability and maintenance. The purpose of this guide is to give web offset printers an overview of maintenance as part of the production system and to provide practical ideas to make it more effective. It draws strongly on the methodology of Total Productive Maintenance (TPM) developed by Seiichi Nakajima that integrates preventive, predictive, quality and autonomous maintenance.

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How To Get Colour Approved Rapidly & Maintain It

Published by Web Offset Champion Group

This guide addresses both the on-press aspects of Colour OK and the total process that begins with the specification and creation of the printed job — the workflow begins with the finished job. Complete digital workflows have led to increased customer requirements for verifiable quality control, use of industry standards, and closed-loop production control. Optimised performance requires an integrated industrial manufacturing strategy that combines standardisation, process control and defined procedures. Effective colour setting is one of the primary tasks for obtaining a press OK and this depends significantly on how humans see, understand and communicate colour. Effective maintenance and standard operating procedures are other key success factors to ensure rapid start-up, optimum quality, productivity and on-time delivery.

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Environmental Considerations

Published by Web Offset Champion Group

This guide looks at the underlying issues of the 4Es of Energy, Economy, Efficiency, Ecology and how to apply the 4 Rs — Redesign, Reduce, Reuse, Recycle — to improve overall performance. A responsible environmental policy has compelling business advantages — the opportunity to reduce costs, increase competitiveness, become more innovative and enhance staff and customer confidence, whilst avoiding the potentially expensive risks of non-compliance. Environmental considerations have an important role in improving overall business performance. Product quality is a joint environmental and economic necessity for a profitable Lean & Green Business.

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Total Process Colour Control & Alternative Screen Technologies

Published by Web Offset Champion Group

Digital workflows have increased the speed and efficiency of offset printing. They have also enabled the development of Alternate Screening Technologies (AST) that can add value to offset printed images by improving their visual quality. However, the digital printing workflow chain also has multiple potential sources of colour and quality deviations. This guide focuses on optimising the conventional AM digital workflow process which is also the prerequisite to the successful use of ASTs such as FM, Hybrid FM/AM and high lpi AM screenings.

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Perfectly Finished Printed Products

Published by Web Offset Champion Group

The printed product is the result of a creative design and production process. Finishing is its final stage and cannot be considered in isolation; rather, it is a critical element in an integrated business process. When things go wrong at the finishing stage, often it is because the bindery is so far removed from the design and specification process that meaningful communication has not taken place. The purpose of this guide is to improve results through better communication and understanding amongst all participants in the workflow — designers, print users, publishers, printers and binders, and their suppliers. The quality of a print product is not dependent on a single process step — prepress, print process, press delivery and storage system affect the quality of finishing. Sustained quality and the ideal price/performance ratio can be achieved only through continuous and effective communication and collaboration across the process chain.

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VAPoN Resource Book - Value Added Printing of Newspapers

Published by PrintCity

The printed product is the result of a creative design and production process. Finishing is its final stage and cannot be considered in isolation; rather, it is a critical element in an integrated business process. When things go wrong at the finishing stage, often it is because the bindery is so far removed from the design and specification process that meaningful communication has not taken place. The purpose of this guide is to improve results through better communication and understanding amongst all participants in the workflow — designers, print users, publishers, printers and binders, and their suppliers. The quality of a print product is not dependent on a single process step — prepress, print process, press delivery and storage system affect the quality of finishing. Sustained quality and the ideal price/performance ratio can be achieved only through continuous and effective communication and collaboration across the process chain.

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Watch The Next Step to Wider Roll Widths UWWO

Published by PrintCity

This study has investigated the impact of changing to larger diameter paper rolls from 1250 mm to 1500 mm ? rolls. This evaluation addresses the impact over the complete value chain — from paper making, roll cores, transport, logistics at the print plant and the paster. It does not make specific recommendations as to whether printers should switch to the larger size rolls because viability will depend on each individual company's circumstances.

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Process Colour Standardisation

Published by PrintCity

This guide is to promote the better understanding and use of process standardisation and workflow optimisation and is complementary to the work of ISO, PSO, Fogra, IDEAlliance™, ECI, ICC, and other organisations. Successful implementation of a printing standard normally provides printers with the benefits of improved cost, quality and time performance, with better sustainability and reduced waste. The use and certification of a standard is an increasingly important business requirement for customers who require demonstrable quality control. A survey of over 50 German print users and designers identified their top three top benefits from working with standardised printing companies as improved quality, consistency and reduced errors.

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"Optimised UV Sheetfed Best Practice Guide" Edition 2

Published by PrintCity

This guide improves the understanding of the UV process and, consequently, productivity and quality. It covers economics, the production systems, best practice operation, diagnostics, food packaging and printing on non-absorbent substrates. UV printing and coating is a core technique for Value Added Printing, which provides the widest range of techniques on the widest range of substrates. Optimal quality and productivity can only be achieved through the effective co-operation between suppliers and printers, who benefit by pooling their skills and knowledge. This 64-page guide collects, integrate and disseminates generic process knowledge to all the participants in the production chain.

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PRINTED version available on demand from www.printCity.de

Print: Lean & Green

Published by PrintCity

Productivity benefits from lean manufacturing that also improve green performance from resource and waste reduction. Print's environmental performance has significantly improved since the 1992 Rio Sustainability Declaration. This is the result of introducing more efficient production technologies and techniques. While the initial driver was economic, it then become apparent that significant environmental benefits could be delivered simultaneously — a win-win result. Print's sustainable attributes also have a positive impact on its value both as a media, and for packaging that uses paper and board substrates. This is one part of a dual publication "Print: Seen! Lean & Green" to see the other part go to "Print: Seen!".

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Print: Seen!

Published by PrintCity

Print must be seen, to stand in its own right and be valued as a functional media. Print retains many unique communication attributes that assure its future will be seen, valued and used within the media mix. Print that is seen attracts more sales attention to the product and more value to the printer, publisher and packager. Value Added Printing and Packaging is the only medium that offers an endless combination of colours, surface treatments, shapes, substrates and smells that stimulate our senses to create emotional value and response. Smart printing technologies are further increasing this value proposition. This book reflects the input from PrintCity members and associates, the Stuttgart HdM Media University, FIPP, University of Swansea, and Print Power. This is one part of a dual publication "Print: Seen! Lean & Green" to see the other part go to "Print: Lean & Green"

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Related FREE poster to download : Print: Seen!

Carbon Footprint & Energy Reduction

Published by PrintCity

Climatic and other environmental issues already have an accelerating impact across the industry-wide process and value chain systems of publishers, advertisers, packagers, printers, and their suppliers. The optimum response to the carbon and energy challenge is in collaborative work across the industry value chain on the basis that: 1. Carbon Footprinting is a tool to help reduce carbon emissions but is only one part of sustainability, not the whole, and needs to be viewed within the overall environmental context; 2. Carbon Footprinting is also an evaluation tool to help increase energy efficiency; 3. International harmonisation of carbon footprint definitions, methodology, and data is needed; 4. There is a need to resolve uncertainty on some key issues: energy, biogenic, and end-of-life stage.

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Sustainability & Energy Efficiency
Frequently Asked Questions . . . and Some Answers

Published by PrintCity

Environment issues have become a profound mainstream concern that impacts on every business, government, organisation and individual on the planet. These issues will increasingly dominate the economic, political and social agenda of the 21st century. Climate change, resource availability, waste disposal and pollution are linked to sustainability. Sustainable development is that which meets the needs of the present without compromising the ability of future generations to meet their needs. It is the balance of three interconnected dimensions defined by The Declaration of Rio on Environment and Development in 1992 as environmental protection, economic growth, and social development.

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Energy Efficiency Optimisation for Web Offset Printers

Published by PrintCity

There are three realities concerning energy: supply is limited and it will remain expensive; the cheapest kW of energy is the one not used; and the correlation between CO2 fossil emissions and energy consumption. Effective management of energy (electricity, gas, propane, diesel, petrol) reduces operating costs, improves working conditionsand helps protect the environment.

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Watch the Step to Wider Roll Widths

Published by PrintCity

Ultra Wide Web Offset (UWWO) extends commercial heatset web offset productivity with web widths between 2 m to nearly 3 m. These presses allow production of 80 pages A4 long grain or 96 pages long grain or short grain. Publication gravure has used wide web widths for some time and in recent years most recent new investment has been at widths around 3,8 m and wider, while there has been a significant decline in widths below 3 m.

Key UWWO questions
UWWO presses are breaking new ground in terms of productivity, enabling the offset process to compete successfully in areas previously dominated by gravure. At the same time, they pose new challenges in press design, material science and operational skills to all concerned in building, equipping and running them.

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Productivity Maintenance in the UK Printing Industry

A cross-industry survey from Vision in Print

Cost effective maintenance is a key success factor for all manufacturing businesses. However, it is often perceived as a hidden cost and not as a productivity benefit with an important business impact. Vision in Print initiated an industry-wide maintenance best practice project to define a series of proactive steps that all printers, regardless of size or sector, can take to improve their maintenance processes to lift their productivity and competitiveness. This study used a comprehensive on-line Internet survey of 100 companies combined with selected follow-up visits. The primary dividends from effective maintenance are reduced total operating costs, on-time delivery and consistent product quality. In addition, it preserves expensive equipment assets and reduces lifetime operating costs by minimising wear and replacement of parts. Good maintenance is also environmentally friendly (reduced energy, waste, cleaning materials, noise) and facilitates health and safety compliance.

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Operational Excellence Workbook Series

Published by Printing Industries of America / Author: Kenneth E. Rizzo

Set of 5 workbooks that address: 1:Operational and Performance Excellence — The Shingo Model; 2: Finding Printers' Hidden Waste ; 3: Cleaning and Organizing: 5S for Printers ; 4: Pit Stop Maintenance with TPM; 5: Quick Changeover for Printers.

PRICE for non-PIA Members $120, or $30 each, order from http://www.printing.org/store

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Do PDF/VT Right™: How to make problem-free PDF files for vriable data printing

Published by Global Graphics

Designers and users of variable data print (VDP) can increase production speed by following this independent guide to optimize their PDF files. The best practice guide provides objective information and advice from design to production. It is edited by Martin Bailey, chief technology officer for Global Graphics and an expert on ISO committees for PDF and PDF/VT. It addresses the key theme of not asking the print workflow to do more work than it needs to if there’s no benefit for the designer, marketing department or recipient of the printed piece. The content is supplier independent and endorsed by the PODi and Xplor industry associations. Sponsors include DirectSmile, Global Inkjet Systems, HP Indigo, HP Inkjet High-Speed Production Solutions and Screen.

Publication available in GB : http://www.globalgraphics.com/doPDFVTright/

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Setup Reduction for Printers

Published by Printing Industries of America / co-authors Malcolm G. Keif and Kevin Cooper

Setup reduction is how companies can increase value to their customers. It is not a simple process and this book outlines a method for reducing setup times by using the proven techniques developed as Single Minute Exchange of Dies (SMED). Malcolm Keif and Kevin Cooper outline a 10 step process that can reduce setup times by 50%, or more, by focusing on reducing internal makeready tasks and moving those to external tasks. This in-depth book focusses on all aspects of makeready, from standardizing fasteners to minimizing adjustments, to incorporating parallel processing to error-proofing makeready.

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PRICE for non-PIA Members $40 order from http://www.printing.org/store

JDF Workflow: A Guide to Automation in the Graphic Communications Industry

Thomas Hoffmann-Walbeck and Sebastian Riegel / Stuttgart HdM Media University / translated by John Joseph Dobrowits

Job Definition Format (JDF) and Job Messaging Format (JMF) are based on the XML standard that provide one of the most important recent innovations for print production automation. This book demonstrates that it is more than just a data format by providing a comprehensive examination of the format as well as the workflow that can be built with the help of JDF. Typical graphic communications production processes and their implementation in the JDF model are presented with the help of examples from order management systems, prepress, printing and finishing. Some special issues for package printing are also covered.

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PRICE for non-PIA Members $99 order from http://www.printing.org/store

Guide to Troubleshooting for the Web Offset Press

Published by Printing Industries of America

An indispensable book that helps the press operator analyze more than 100 press problems encountered in all areas of web offset printing, including: infeed, printing unit, ink feed, dampening, plate, blanket, paper, ink, dryer and chill roll, delivery, and print quality. This revised edition has a new layout and binding format to help make this problem-solving guide easier to use.

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PRICE for non-PIA Members $99 order from http://www.printing.org/store

Guide to Troubleshooting for the Sheetfed Offset Press

Published by Printing Industries of America

A handy pressroom guide to sheetfed printing challenge. This quick reference press operator's companion is written by Printing Industries of America experts to helps press operator's analyse over 100 press problems in all areas of sheetfed offset printing. Each chapter includes a general description of the system and the relevant problems with their possible causes and remedies, including illustrations and photographs.

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PRICE for non-PIA Members $99 order from http://www.printing.org/store

Introduction to Densitometry

Published by Printing Industries of America / Author Peter Brehm

This book is a user's guide to print production measurement using densitometry. It explains the basics of densitometry, offers tips on their use, and discusses standards and verifying conformance to standards. Contents include :

  • Basics of Densitometry
  • How Densitometers Work
  • Wide-band, Narrow-band, and Bandwidth
  • Polarized Filters Explained
  • Using Densitometers
  • Improvements in Densitometry
  • Standards and Verifying Conformance to Standards

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PRICE for non-PIA Members $35 order from http://www.printing.org/store

Guide to Print Production

Published by by IDEAlliance

Best Practices & Specifications for Printing Version 12

The rules for excellence in graphic design and media production apply equally to a billboard, bus wrap, an advert in a magazine and a product on a store shelf. In the 12th Edition of the IDEAlliance Printing Guidelines, best practices are categorized and the demands of evolving customer needs are addressed, along with the challenges of acting globally and changes in technology. From specifications such as GRACoL and SWOP to updates in lighting and measurement, and the addition of G7 specification TR015, this publication addresses the latest best practices in printing in North America and Internationally.

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PRICE for non-PIA Member Price: $25 order from http://www.idealliance.org