“Develop success from failures. Discouragement and failure are two of the surest stepping stones to success.”
Advancements in Printing
UNIT-1
1. Inkjet Printing
Introduction:
Working Principle:
1. Ink Reservoir: Holds liquid ink.
2. Nozzles: Micro-nozzles eject droplets onto the substrate.
3. Droplet Formation: Two main types:
4. Substrate Movement: Paper or material moves to create the full image.
Advantages:
Disadvantages:
Applications:
2. 3D Printing
Overview:
Working Process:
1. Design: Create a 3D model using CAD software.
2. Slicing: Software slices the model into thin layers.
3. Printing: Layer-by-layer deposition using materials (plastic, metal, resin).
4. Post-Processing: Curing, finishing, or support material removal.
Common 3D Printing Technologies:
Materials Used:
3. 4D Printing
1. Material Selection: Use smart materials that react to heat, light, moisture, or pH.
2. Printing: Similar to 3D printing, but using programmable materials.
3. Transformation: After printing, the object can self-assemble, fold, expand, or move when triggered.
Digital Printing
Process of Digital Printing:
1. Design & Prepress:
2. Rip & Screening:
3. Printing:
4. Finishing:
Advantages of Digital Printing:
Disadvantages of Digital Printing:
Types of Digital Printing Processes:
2. Hybrid Printing
Hybrid Printing Process:
1. Prepress & Design: Artwork is prepared for both digital and conventional printing stages.
2. Conventional Printing Stage: Base layers, backgrounds, and large-volume graphics are printed using offset, gravure, or flexography.
3. Digital Printing Stage: Variable data, personalization, numbering, short-run modifications, or spot graphics are added.
4. Finishing: Lamination, varnishing, die-cutting, and packaging.
Advantages of Hybrid Printing:
Types of Hybrid Printing Integration:
UNIT-2
Introduction to Security Printing
Security Printing refers to printing methods and technologies used to protect documents, currency, and products from counterfeiting, tampering, or unauthorized reproduction.
Objective:
Advanced Security Printing Features
Security features are classified into overt, covert, and forensic features based on visibility and complexity:
Categories of Security Printing Features
1. Overt Features: Visible to naked eye
2. Covert Features: Require special tools to verify
3. Forensic / Intrinsic Features: Detectable under lab testing
Benefits of Advanced Security Printing
Introduction to Imaging Technologies
Imaging technologies in printing refer to methods that transfer digital artwork directly onto printing surfaces (plates, screens, or cylinders) without intermediate film, improving efficiency, precision, and print quality.
Objectives:
Computer-to-Plate (CTP)
Definition:
Computer-to-Press (CTP / Direct Imaging)
Methods:
1. Direct Plate Imaging: Presses with inbuilt plate imaging system.
2. Digital Printing Presses: Inkjet or electrophotographic presses that print directly from digital files.
Computer-to-Cylinder (CTC)
1. Digital artwork is processed in RIP.
2. Laser or electroplating techniques engrave the image onto the cylinder surface.
3. Cylinder is mounted on the press for high-volume printing.
Computer-to-Screen (CTS)
1. Digital file is RIP processed.
2. Laser exposes the photosensitive emulsion on the screen.
3. Screen is used to print designs on textiles, packaging, or labels.
Square Spot Dot Technology
UNIT-3
Concept of Colour Management
Colour Management is a systematic approach to control and reproduce consistent and accurate colours across different devices (monitors, printers, cameras, and presses).
Colour Calibration
Steps:
1. Monitor Calibration: Adjust brightness, contrast, gamma, and white point using hardware tools (colorimeters).
2. Printer Calibration: Print test charts, measure colour output, and adjust settings.
3. Scanner Calibration: Ensure scanned images maintain accurate colour representation.
Benefits:
Colour Management Software (CMS)
Popular CMS Tools:
Functions:
Colour Matching Techniques
Methods used to achieve consistent colour across devices:
1. Visual Matching: Comparing printed samples to originals; subjective and less precise.
2. Instrumental Matching: Using spectrophotometers or colorimeters to measure and reproduce colour.
3. Profile-Based Matching: Using ICC profiles to convert colours accurately between devices.
4. Pantone Matching System (PMS): Standardized colour guides for spot colours in packaging and branding.
Colour Models
Colour models are mathematical representations of colour:
Colour Model
Description
Applications
RGB
Red, Green, Blue; additive colour
Monitors, digital screens, cameras
CMYK
Cyan, Magenta, Yellow, Black; subtractive colour
Printing (offset, digital, flexo)
Lab / CIE
Lightness (L), a (green-red), b (blue-yellow); device-independent
Colour conversion, accurate measurement
HSB / HSL
Hue, Saturation, Brightness/Lightness
Graphic design and image editing
ICC Profiles
Types of ICC Profiles:
Purpose:
Colour Management Workflow
Typical Workflow in Printing:
1. Source Image Preparation: RGB or Lab colour images
2. Device Profiling: Calibrate scanner, monitor, printer
3. Colour Conversion: Convert from source colour space to target device (e.g., RGB → CMYK) using ICC profiles
4. Soft Proofing: Preview final print on calibrated monitor
5. Printing & Proofing: Print sample and adjust colour if required
6. Final Print Production: Maintain consistent colour across batches
Diagram of Workflow (Simplified):
Digital File → CMS → Device Calibration → ICC Profile Conversion → Soft Proofing → Printing → Output Verification
8. ISO Standards for Colour Management
9. Equipment Used for Colour Management
Equipment
Purpose
Spectrophotometer
Measures colour on printed samples
Colorimeter
Monitors calibration and verification
Densitometer
Measures ink density on press
Monitor Calibration Device
Calibrates display for accurate preview
Digital Proofing System
Soft-proof and hard-proof verification of final output
Light Booth / Viewing Cabinet
Standardized lighting conditions for visual assessment
10. Key Takeaways
Advanced DTP Software
Popular Advanced DTP Software:
Software
Introduction
Adobe InDesign
Professional page layout and design software
Magazines, brochures, books, packaging design
QuarkXPress
Powerful layout and typesetting tool
Newspapers, books, packaging
CorelDraw
Vector graphics and illustration software
Labels, flexo/packaging graphics, signage
Affinity Publisher
Modern, cost-effective layout software
Books, brochures, marketing materials
Scribus
Open-source DTP tool
Small-scale publications and e-publishing
Applications of Advanced DTP Software:
RIP Software (Raster Image Processor)
Popular RIP Software:
CIP3 (Computer Integrated Prepress, Press, and Postpress)
CIP4 (Job Definition Format - JDF)
G7 Specification
Key Features:
UNIT-4
Concept of IoT
Internet of Things (IoT) refers to a network of physical devices embedded with sensors, software, and connectivity that enables them to collect, exchange, and analyze data over the internet.
Key Characteristics:
Examples in everyday life:
Applications of IoT in Printing
IoT can revolutionize the printing and packaging industry by connecting machines, processes, and supply chains for greater efficiency:
IoT Application
Benefits
Smart Presses
Printing presses equipped with sensors for temperature, ink density, and speed
Real-time monitoring, predictive maintenance, reduced downtime
Remote Workflow Management
Cloud-connected devices manage jobs, approvals, and scheduling
Increased efficiency, reduced manual intervention
Inventory & Material Management
Sensors track paper, ink, and substrates
Just-in-time inventory, reduced waste
Predictive Maintenance
Sensors detect wear and tear on rollers, motors, or dryers
Reduces unplanned downtime and maintenance costs
Quality Monitoring
Inline cameras and sensors detect misprints, colour variations, or defects
Consistent print quality, less rework
Packaging & Label Tracking
RFID or barcode-enabled IoT devices track printed packaging
Supply chain traceability and anti-counterfeiting
Energy Management
IoT monitors energy consumption of machines
Optimized energy use, cost savings, and reduced carbon footprint
Customer Interaction
Connected devices allow remote order status, print customization, and data analytics
Improved customer service and personalized printing
Scope of IoT in Printing
1. Digital Printing Presses:
2. Packaging Industry:
3. Supply Chain & Inventory:
4. Maintenance & Efficiency:
5. Integration with ERP & Cloud Systems:
IoT and Sustainability in Printing
IoT promotes sustainable practices in the printing and packaging industry:
Area
IoT Contribution
Sustainability Benefit
Energy Efficiency
Monitors and optimizes machine energy use
Reduced carbon footprint and energy costs
Waste Minimization
Tracks ink usage, paper waste, and rejects
Less material waste and reprints
Resource Optimization
Just-in-time inventory management
Reduces overproduction and storage needs
Preventive Maintenance
Reduces machine failure and downtime
Minimizes energy-intensive emergency repairs
Smart Packaging
IoT-enabled recyclable packaging and tracking
Promotes circular economy and traceability
Example:
Green Printing
Key Practices:
Erasable Printing Technology
Technology:
Online Printing Platforms
Features:
Examples:
Augmented Reality (AR) in Printing
Concept of Yellow Bar
Printed Electronics
Technologies:
DI (Direct Imaging) Presses
Lenticular Printing
Customized Printing
Hybrid Printing