Handbook of Print Media

Springer-Verlag Berlin Heidelberg GmbH

Helmut Kipphan CEd.)

a dbook
of Print Med-a
Technologies and Production Methods
Volume 1

Including 1275 figures, mostly in color

and 92 tab les

Springer
Prof. Dr.-Ing. habil. Helmut Kipphan
Heidelberger Druckmaschinen AG
Kurfiirsten-Anlage 52-60
69115 Heidelberg
Germany

ISBN 978-3-642-63142-9 ISBN 978-3-540-29900-4 (eBook)

DOI 10.1007/978-3-540-29900-4
Cataloging-in-Publication Data applied for

Handbook of print media: technologies and production methods 1 ed. Helmut Kipphan. - Berlin; Heidelberg ;
New York; Barcelona ; Hongkong ; London ; Milan ; Paris; Singapore; Tokyo: Springer, 2001

This work is subject to copyright. Ali rights are reserved, whether the whole or part of the material is concerned, specifically the rights of transla-
tion, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in other ways, and storage in data banks. Duplication
of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current ver-
sion, and permission for use must always be obtained from Springer-Verlag. Violations are liable for prosecution under German Copyright Law.

http://www.springer.de
© Springer-Verlag Berlin Heidelberg 2001
Originally published by Springer -Verlag Berlin Heidelberg New York in 2001
Softcover reprint of the hardcover ISt edition 2001

The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific state-
ment, that such names are exempt from the relevant protective laws and regulations and therefore free for general use.
Cover design: de'blik, Berlin
Production manager: Ursula Weisgerber, (Springer, Berlin)
Typesetting and layout: medio Technologies AG, Berlin
Finishing: Fikentscher, Darmstadt
SPIN: 10764981 62/3020 - Printed on acid-free paper - 5 4 3 2 1 O
 v

Preface

The German edition of the Handbook of Print Media pictures and graphs for enhancing the educational and
- Technologies and Production Methods was pub- technological presentation.
lished and introduced to the market during the book
fair in Frankfurt/Main in October 2000. The handbook is written in "international" English.
The translation work for the English edition was The rules for syllable separation and punctuation are
started in 1999 immediately after the manuscripts for based mainly on "Merriam-Webster's Collegiate Dic-
the German edition had been prepared. tionary': and "The Chicago Manual of Style". The ty-
The translation of the German preface follows this pographical details, the fonts and page layout are opti-
preface. The German preface describes in detail the ori- mized for easy reading.
gins of this handbook, the goals regarding contents and I would like to thank the whole team working on the
readership, and in particular the comprehensive coop- translation, especially the afore-mentioned experts for
eration with experts from academia and industry in the their patience, efforts and support in creating a valu-
fields of science, research, development, education and able international handbook, which is now ready for
from publishing and the communication industry worldwide use.
worldwide.
I have expressed my recognition and gratitude to the The units for technical specification/ quantities are stat-
many experts and partners in this cooperation and ed in the international SI-system (metric) and only a
would like to do so again here. few quantities are stated additionally in imperial units
directly in the text. Detailed tables of physical/technical
The translation for the English edition was done by a quantities and conversions are given in Section 14.2.
team of international translators, headed by Dr. Rene We took special care to choose terminology which is
Bosewitz (The Translators AG, Heidelberg, Germany). used and understandable worldwide and exploited this
The proof-reading and refinement, especially re- consisteptly throughout the whole book (sometimes
garding specialist terminology and the optimization of giving additional terms). This was a great challenge and
the description of the technical content, was supported the reader should excuse us if some terms are different
from the beginning by Professor Frank Romano and from those he is familiar with.
Professor Frank Cost of the RIT (Rochester Institute of
Technology)/College of Imaging Arts & Science in The bibliography (references and further reading) in
Rochester/NY (USA) and myself. the several sections/chapters is basically identical to
In my capacity as editor, author within the large group that of the German edition. There is, however, some
of authors, and project manager I was responsible for the additional information from international publica-
content of the handbook and its scientific and technical tions to support the English speaking readership. In
quality. I was deeply involved in the process of enhanc- any case where an English edition exists we added this
ing the translation and learned a lot with the translators in or replaced the German edition with this.
when explaining the technical facts, answering questions Most of the addresses, for example of research insti-
and showing what had to be described. tutes and associations, are stated in their native lan-
This handbook is, therefore, not "only" a translation guage. We have not given a translation for these. If of-
of the German edition. It includes many improve- ficial names exist in English, in some cases we have sub-
ments, additional information and descriptions in text, stituted them for the German or added them in.
VI

Together with best regards and wishes from Bernhard media. The handbook should also help to ensure that
Schreier (DipL-Ing.), the Chairman of the Manage- the influence of innovations, advanced and new tech-
ment Board of Heidelberger Druckmaschinen AG to nologies, market and customer demands on these in-
all readers, partners and experts from the printing, dustries and their further growth be evolutionary
publishing and communications industry, I hope and rather than revolutionary, and that print media con-
trust both personally and on behalf of Heidelberg that tinue to contribute to the maintenance, expansion and
readers will gain an equal amount of pleasure and prof- further development of a high degree of education, cul-
it from this book, the Handbook of Print Media. It ture, progress and quality oflife throughout the world.
should contribute to ensuring the continuing eco-
nomic, high-quality production and availability of Helmut Kipphan
print media in today's age of information - both in Heidelberger Druckmaschinen AG
conjunction as well as in competition with electronic Heidelberg, December 2000
 VII

Preface of the German Edition

The technological change and evolution in the printing, In order to produce and supply media products and
publishing and communications industry and increasing services, companies, management and technical per-
market requirements in terms of quality, costs and dis- sonnel, trainees, teachers and instructors must adapt
tribution of print media, have led to a considerable equally to existing and continually developing new
change in the technologies and processes used for their structures, technologies and opportunities in today's
production. Digitalization, automation, synergistic tech- information society. Investment decisions must be
nologies and innovations are further signs of improve- made from a commercial, technical, market and cus-
ments, developments and new production methods and tomer-specific point of view, based on a wide range of
processes. Demand on print media is also influenced by business and technical performance factors and criteria.
the spread of electronic media together with new possi- Information and knowledge on this meteoric devel-
bilities in information storage and availability, produc- opment and new possibilities have been published in
tion and design of print media and the creation of new numerous books and papers in technical literature and
multimedia products, in particular as well as the work- presented and discussed at national and international
flow stages involved in media production. symposia and conferences, but mostly only describing
Processes and equipment used to produce print me- specific subjects. However, it is difficult for the indi-
dia require the use of a wide range of innovative tech- vidual to keep up-to-date and form a comprehensive
nologies and components from all areas of technology picture based on traditional technologies and process-
and industry - the need for cross-functional, interdis- es. In this respect the far reaching content and didactic
ciplinary working is particularly strong in the graphic design of the Handbook of Print Media should make
arts industry and therefore involves cooperating with it an essential aid and tool in everyday practice.
partners from many industrial sectors.
It is the advances in computer and networking tech- The original ideas for producing a handbook of print
nology, digital control and processing of production media are based on my conversations in June 1996 with
equipment within the total production chain in print Dr. Hubertus v. Riedesel (Dipl.-Phys.) of the Springer
media creation - that is from concept to the final print Publishing Company in Heidelberg during one of the
media product - which more than anything else have symposia of the "Rhein-Neckar - discussion group for
enabled the traditional production areas of prepress, Physical Research in Industry and University" (an ini-
press and postpress to evolve together and be realized tiative of the University of Heidelberg and the indus-
for practical use. try). Conversations between the management of the
Digital workflow has become a reality, Computer to ... publishing house, and Hartmut Mehdorn (Dipl.-Ing.),
technologies characterize production with their wide Chairman of the Management Board of Heidelberger
range of possibilities for realizing digital print produc- Druckmaschinen AG at that time, and myself provid-
tion. Novel printing technologies, production methods ed the impetus for putting these ideas into practice.
and strategies have become possible and are being used Fascination with the wide range of subject matter and
in practice. products of the graphic arts industry and the experience
Digitalization has also created the pre media sector in of two successful globally active enterprises based in the
which information for distribution is created as a dig- same city of Heidelberg led to the unanimous decision
ital master that forms the basis for duplication via both by the Board of Heidelberger Druckmaschinen AG in
print media and electronic media. December 1997 to publish the "Handbook of Print Me-
VIII

dia - Technologies and Production Methods" in Ger- • training, education, research, development trends
man in the year 2000 and an English edition soon after. and strategies;
It was, in particular, Hartmut Mehdorn, who under- • state-of-the-art production equipment, systems
took to meet the urgent need for further education and and technologies, taking account of the products of
training in the printing and publishing industry and numerous well known manufacturers from around
supported the project through his creative and ex- the world;
tremely active involvement. • environmental protection and safety technology;
The following events lend particular significance to • historical evolution of printing;
the year 2000 for the graphic arts industry and Heidel- • reviews of standards, norms, training centers and
berg: the 60ath birthday of Johannes Gutenberg, the in- research establishments, societies, associations and
ventor of letterpress printing using movable metallic organizations of the printing and publishing indu-
type, the required tools and a printing press; the 150th stry, as well as international technical conferences,
anniversary of Heidelberger Druckrnaschinen AG and, etc.
linked to this, the inauguration of the Print Media
Academy based in Heidelberg. The handbook should therefore serve as a standard ref-
With the Print Media Academy as a new center for erence for technical communication and further edu-
communication, qualifications and knowledge within cation; it should provide technical personnel and man-
a worldwide network for the whole printing and pub- agers of printing and publishing houses, of the graph-
lishing industry, and the Handbook of Print Media, ic arts and communications industry, supply industry,
Heidelberg continues to contribute to the improve- scientific bodies, trade associations and experts in re-
ment and dissemination of knowledge about the re- search and education, trainees and students with com-
quirements of industry and promote the advancement prehensive information. In addition, however, it
of the graphic arts and communications industry. should give those who are not familiar with the indus-
try the opportunity to learn about the theory and prac-
An examination of the current literature showed that tice of print media production and to develop an
a large number of good text books and much educa- awareness of new areas.
tional literature is already available, covering most
subjects and areas of the printing and publishing in- The wide scope of the handbook means that there has
dustry as well as a large quantity of individual publi- been a deliberate use of repetition in the individual
cations, but also that there is considerable demand for chapters. This enables the reader to first become famil-
an up-to-date, clear and comprehensive presentation iar with the broad area of a subject and then use cross-
of the whole subject. referencing to study the complementary information
Thus, the concept of the handbook took shape, whose given in other chapters.
main focus was the need to give state-of-the-art treat- The handbook provides a solid foundation for ac-
ment to the whole spectrum of modern print media quiring basic information and gaining an understand-
production and to make clear, topical facts available, ex- ing and knowledge of the subjects' interrelationships.
plaining subjects, such as the following in particular: References to specialist and complementary literature
help to provide more in-depth information. It repre-
• traditional technologies and new innovative pro- sents a building block and reference work for training
cesses in all stages of production; programs and further education - also in the context
• detailed treatment of novel digital printing techno- of the programs of the Print Media Academy - and is
logies, especially non-impact printing processes; aimed at an international readership having a broad
• the positioning of print media, electronic media range of different interests.
and multimedia; The CD-ROM that accompanies the handbook
• the positioning of the various printing processes makes it a true multimedia product. The CD-ROM in-
based on their performance characteristics and the cludes the complete handbook, enables a full text
market segments of print media; search and contains additional aids to provide a con-
• presentation of the trends in the production of venient and focused method of searching and infor-
print media, taking economic and technological re- mation gathering. It also provides a user friendly guide
quirements into account; to the extensive text and the numerous figures.
 IX

There is an up-to-date explanation of the state-of-the- Chemnitz supported the coordination of the technical
art with respect to subject matter, referring in general matter. In closest collaboration with the editor they
to the end of 1999. However, many new products and contributed to ensuring that the manuscripts met the
technologies, which were not to be publicized until quality demanded of the handbook in terms of content
May 2000 at Drupa (the world's largest exhibition of and educational value, and that the contributions were
print media) have already been taken into account. as consistent as possible.
Statements on the trends and forecasts are based on The English translation of the handbook was begun
current facts and extensive experience as well as infor- immediately following production of the German
mation obtained around the world. manuscript. The English translation team was sup-
The editor and publisher have agreed to update the ported by international experts with experience in the
handbook in subsequent editions, so that it forms a graphic arts industry, Professor Frank Cost and Pro-
standard work for the production of print media. fessor Frank Romano of the RIT (Rochester Institute
of Technology)/College of Imaging Arts & Sciences in
It is with pleasure that I undertook the extremely stim- Rochester/NY (USA). They undertook the task of per-
ulating tasks which Heidelberger Druckmaschinen AG forming a general check of the translations produced
entrusted to me as leader of the project to create the regarding the language and then once again for con-
handbook, as well as taking charge of the technical con- tent, resulting in a number of improvements. This al-
tent, and acting as the editor. This afforded me a par- so meant that the experience and interests of interna-
ticular opportunity and responsibility for creating and tional experts, teachers and readers could be taken in-
making the subject matter available while Springer, in to account to an even greater extent.
close cooperation, undertook the production and mar-
keting. Special thanks are also due to the employees in my
The diverse subject matter as well as Heidelberg's aim department of Technology & Innovation Research,
to represent technologies, products and systems as in- Dr. Martin Schmitt-Lewen (Dipl.-Phys.) and Walter
dependent of their manufacturer as possible led from d'Heureuse (Dipl.-Ing.), who continually supported
the outset to the idea of creating the handbook by em- me during the whole project through their critical and
ploying a team of authors drawn from science, re- constructive contributions on the clarification of tech-
search, education, academia and industry. This was nical questions, but also for their patience and under-
coupled with the skill, knowledge, competence and ex- standing in the often difficult situations caused by
perience of the Heidelberg Group, but predominantly scheduling. Special mention goes to their support in
with external authors. working on the manuscripts for proof-reading and
One of the greatest challenges was to set up the team correction as well as searching for and acquiring mate-
of authors, to discuss and agree on the subject matter rial for illustrations. Thanks also to SciTech Consul-
and content, to match the authors to the current tasks tants GmbH/Heidelberg, Germany, who worked in
and to complement the team during the editing process. close cooperation with us from the beginning of the
The initial meeting of a core team of authors took place project regarding communication and timing between
in Heidelberg in March 1998. Additional authors were the various parties for both the German and English
still being included in the team until August 1999. edition. The work included the competent and accu-
A great deal of thanks is due to all authors. They per- rate proof-reading of all the versions of the chapters
formed their tasks well and were willing to agree to sug- right up to going to print.
gestions and improvements so that the handbook
could appear to come "from a single mold" despite the I am particularly keen to thank all of the companies,
large number of authors. Thanks also go to the many experts and customers all over the world for the many
experts, who are not named here but whose words and conversations, the advice, suggestions and constructive
deeds contributed to the content and progress of the criticism on the wide range of subjects and queries on
project. the production of print media and the demands on the
means of production. It was only with this information
Professor Arved C. Hubler (Dr.-Ing.) and Professor and support, mainly based on years of close coopera-
Wolfgang Beier (Dr.-Ing.) of the Institute for Printing tion and continual personal contacts, that we could
and Media Technology at the Technical University of take an up-to-date and comprehensive view of the
x

interests and requirements of the users of production time and to make it available to a broad readership. It
equipment and systems as well as their customers. This was always a common goal for me, Heidelberg and
applies both to the gathering of the material for the Springer to produce the very highest quality. Readers
book and the handling and treatment of the individual and users of the handbook are urged to provide sug-
topics. This ensured that the handbook relates to in- gestions and advice on how it may be updated and im-
dustrial practice, lends equal support to owners, man- proved. This information will help in the preparation
agers and employees in the various workplaces of a of a subsequent edition broadly based on a desire for
printing/publishing company and also offers trainees continuous improvement.
and students useful, practice-oriented information,
knowledge, skill and experience. Personally and on behalf of Heidelberger Druck-
Many thanks also for the support received from col- maschinen AG and together with the best regards and
leagues and experts in the Heidelberg Group world- wishes of the Chairman of the Management Board of
wide as well as the numerous contacts in companies in Heidelberg, Bernhard Schreier CDipl.-Ing.) to all read-
the supply industry, partners in cooperation and com- ers, partners and experts in the printing, publishing
petitors, as well as experts and partners in institutions and communications industry, I hope and trust that
and organizations for industrial and academic re- readers will gain an equal amount of pleasure and prof-
search. it from this book, the Handbook of Print Media. It
should help in allowing print media to continue to be
The selection and creation of illustrations posed a par- produced and supplied economically and in high qual-
ticular challenge and represented a subject of special ity in today's age of information - both in conjunction
interest to me personally, firstly with respect to the as well as in competition with electronic media. It
quality of the images and secondly from the point of should also mean that the influence of innovations, ad-
view of a representative selection of examples of prod- vanced technologies and market and customer de-
ucts from as many suppliers as possible. Special thanks mands on these industries and their further develop-
to all companies and experts whose understanding and ment will be evolutionary rather than revolutionary
helpfulness provided us with illustrations and infor- and that print media will continue to contribute to the
mation either directly or indirectly. Great care has been maintenance, expansion and further growth of a high
taken to name all sources; if there are omissions, please degree of education, culture, progress and quality of
accept our apologies. life throughout the world.

The skills, competencies, abilities, experiences and

partners of the Heidelberg Group and Springer were Helmut Kipphan
used to produce a high-quality handbook in terms of Heidelberger Druckmaschinen AG
content, illustration and design in a relatively short Heidelberg, April 2000
 XI

Authors and their Contributions

As explained in the preface, a team of authors from sci- butions to the content and scope of the section. Sections
ence, research, academia and industry was formed to or chapters which were written by one author in total
create the handbook. Editing of the diverse and com- or as the main author, are in bold print in the following
prehensive subject matter resulted from close coopera- list, while co-authors are named for sections or chap-
tion with Professor Helmut Kipphan (Dr.-Ing. habil.), ters in normal type (for contributions which are rough-
the editor, who was also in charge of the content and ly equal there is no distinction made between author
scope of the handbook, its technical and scientific qual- and co-author).
ity and who is also the main author. All contributions to the handbook were edited with a
Many contributions - sections as well as complete desire for unity of style of text, images and graphics, a
chapters - were produced by individual authors. Nu- clear structure and an educationally useful design with
merous sections also arose out of the cooperation of the support of the editor's staff, colleagues and the co-
several authors, mainly author and co-author. Co-au- ordinators in cooperation with all of the authors.
thors are named if they have made important contri-

Beier, Wolfgang, Prof. Dr.-Ing. Dorner. Gerhard 0 .• Dipl.-Ing.

lnstitut for Print- und Medientechnik, Berllfsgenossenschaft Druck und Papierverarbeitung,
Techni che Universitat Chemnitz, (In titution for Statutory Accident Insurance and
(Institute for Print and Media Technology, Prevention in the Printing and Paper Converting
Technical University of Chemnitz), Chemnitz lndustry),Wiesbaden
145 • 2·3 • 3-l (without 3·1.7) • 14·1.1,14·2 • 15· 13.2 .2 .

Briies. Stefan. Prof. Dr. rer. nat. Friedl. Friedrich. Prof.

Kommunikation technologie-Druck, Bergische Hochschule for Gestaltung,
Universitat-Ge amthochschule Wuppertal, (Art Academy), Offenbach
(Department of Communication Technology - Print 1.2 .1.
Media, University of Wuppertal), Wuppertal
1.4·1,1.4·2 • 3.2.6,3.2.9, 3.2.U. Fuchs. Boris. Dipl.-Ing.
Frankenthal
Dalton. Keith. BSc (Hons) 1.6.2.2,1.9.2 • 2.1.3,2.1.6.2, 2.2.1,2.2.2,2.2.4 • 8.1.1
Heidelberger Druckmaschinen AG, Heidelberg (without 8.1.1.5) • 13.1.1.
1·1.4, 1.1.5 • 13.3.
Hiibler, Arved C., Prof. Dr.-Ing.
Dolezalek. Friedrich. Ph.D. In titut for Print- und Medientechnik,
FOGRA Forschllngsgesellschaft Druck e.Y., Technische Universitat Chemnitz,
(Graphic Technology Research Association), (Institute for Print and Media Technology,
Milnchen Technical University of Chemnitz), Chernnitz
3.1.7,3.2.2 • 13.2.3 • 14·4,14·5,14·6. 1.9.1,1.9·3 • 8.1.2,8.1.3 • 9.1,9. 2 • 14.5-14.7 • 15.
XII Authors and their Contributions

Ipsen. Heiner. Prof.. Dipl.-Ing. Ritz, Axel. Prof .• Oipl.-Phys.

FB Druck, Verpackung, Kommunikationstechnik, FB Druck. Verpackung, Kommunikationstechnik.
Hochschule fur Druck und Medien, Hochschule fur Druck und Medien,
Fachhochschule Stuttgart, Fachhochschule Stuttgart,
(Department for Print, Pack, Media, University of (Department for Print, Pack, Media, University of
Applied Sciences of Stuttgart), Stuttgart Applied Sciences of Stuttgart), Stuttgart
2·4,2·5·4· 1.4.5 • 2.1.2.

Kern. Jurgen. Dr. rer. nat. Ruder. Rudolf. Prof. em. Or.-Ing. habil., Or.-Ing. E.h.
Heidelberger Druckmaschinen AG, Heidelberg Chemnitz
13.2.1. 1.6.1, J.6.2.1.

Kipphan. Helmut. Prof. Or.-Ing. habil. SchUipfer. Kurt. Prof. Dr.

Heidelberger Druckroaschinen AG, Heidelberg Eidgenossische Materialprtifungs- und
1.1.1,1.1.3,1.2,1.3.1,1.3.2,1.3.3,1.4-1- 1.4.4,1.4.5,1.5, Forschungsan talt (EMPA).
1.5.2.8,1.7 • 2.1.1,2.1.2,2·1.3,2.1·4,2.1·5,2.1.6.1,2.1.6.2, (Swiss Federal Laboratories for Material Testing),
2.1·7, 2.3, 2·4·3, 2.5.1, 2·5·3 • 3.2.1,3.2-7,3.2.8, 3·2.n . St. Gallen, Switzerland
4·1,4·3,4·4,4·5 • 5·1 -5·9 • 6.1-6·4 • 7.1-7.3 • 8.1.1·5, 3.2.3, 3·2.10.
8.2 • 9.1.2-9.1.4,9.2 • 10.1-10.5 • 11.1,11.6,11.7 •
12.1-12-4 • 13.1.1, 13.1.3.5 • 14·1.1,14.1.2, 14.1.3,14·2, SchOnhut. Jurgen. Dr. phil.
14.3.1,14.3.2, 14·5-14·7 • 15· Fraunhofer-Institut fur Grafische
Datenverarbeitung (IGD).
Liebetruth, Hartmann. Prof. Dr. Dr. h.c. (Fraunhofer Institute for Computer Graphics).
Komm u nikationstechnologie-Druck, Bergische Darmstadt
Universitat-Gesamthochschule Wuppertal, 1.1.1,1.1.2.1.1.3, 1.2.2- 1.2.4,1.2.5,1.2.6 • 8.2 • 11.1.
(Department of Communication Technology - Print 1l.2-11.5, 11.6, 11.7.
Media, University of Wuppertal) , Wuppertal
13·1.2. Seydel . Michael. Or.-Ing.
Heidelberger Druckmaschinen AG. Heidelberg
Nestler. Rainer. Prof. Or.-Ing. 4. 2 ,4.3.
FB Druck, Verpackung, Kommunikationstechnik,
Hochschule fur Druck und Medien, Tessmann. Uwe. Or.-Ing.
Fachhochschule Stuttgart, Heidelberger Druckmaschinen AG, Heidelberg
(Department for Print, Pack, Media, University of 13.1.3 (without 13.1.3.5).
Applied Sciences of Stuttgart), Stuttgart
1.8 • 7.1-7.3. Thomas. Hermann. Oipl.-Ing.
Darmstadt
Neumann. Richard. Oipl.-Ing. 2·5·1-2·5·3·
Lengerich
1.6.2.3 • 2.2.3. 2.3. Walenski. Wolfgang
Bergisch-Gladbach
Nicolay. Klaus-Peter, Oipl.-Ing. 1.5 (without 1.5.2.8).
Arcus Communications & Design, Bruttig-Fankel
3.2.1, 3.2.4, 3.2.5, 3.2.7, 3.2.8, 3.2.11, 3.2.12.

Rech. Helmut. Prof. Or.-Ing.

lnstitut fur Technologie & Planung Druck,
Hochschule der Ktinste,
(The Berlin University of Arts), Berlin
1.3.1.1.3.2,1.7 • 2.1.1.
 XIII

Table of Contents

1 Fundamentals 1.4 Print Quality 68

1.4·1 Color/Color Theory ...... . ... . . . . ... . . . 68
1.1 Communication Technologie ........ . . . 4 1.4·2 Color Image Composition .............. . 79
1.1.1 Print Media ................. . ........ . 4 Halftone Process/Screening .... .. .. . .... .
1.4·3 90
1.1.1.1 Books .................... . ... . ...... . 5 1.4-4 Quality Control/Measurement
1.1.1.2 Magazines .............. .... ... . ..... . 5 Techniques ................ . . . ........ . 99
1.1.1.3 Newspapers ........... . . . ... . . . . . .... . 6 Color Measurement ........ . . .. ....... . 100
1.404·1
1.1.1.4 Brochures ............ . ... .. . ..... .... . 6 1.4.4.2 Color Register ........... . .... . .. . . . .. . 108
1.1.1·5 Other Printed Media . . ....... ... ....... . 6 Measurement of Gloss . . .... . . . .. . .. . .. . no
10404·3
1.1.2 Electronic Media .. .. . . .. . . .. .... . ... .. . 6 Surface Finishing . .. . .. . .. . .. . . ..... . . . III
104·5
1.1.3 Multimedia . .... . .. . .... . . .. . . .. . . . .. . 7 Characteristics of Surface Finishing . . . .. . . III
104·5-1
1.1.4 Distribution and Market Volume . . . . .. .. . 8 1.4.5. 2 Surface Finishing Techniques . . . . .. . . .... . 113
1.1.5 Trends and Scenarios for the Future .. ... . . 10
1.1.5.1 Changes in the Traditional Print Media Materials 117
1·5
Printing Sector .......... ... . . . .. ...... . 10
Substrates ................. . . . . . ...... . 117
1.5·1
1.1.5.2 Integration of New Media . . ... . . . ...... . II
1.5·2 Printing Ink1.7 Drying Methods ' .... . 130
1.5·2.1 Structure and Keqmrements ... . . . . . . . .. . 130
1.2 Production of Print Medja 14 1.5·2.2 Offset Printing Inks ............ . . . . . ... . 137
1.2.1 Layout, Typography, Graphic Design 15 Gravure Printing Inks ......... . . . . .. . . . . 137
1.5·2·3
1.2.1.1 Type . ................. . . . . ... ....... . 15 Flexographic Printing Inks . ... ... . . .. . .. . 139
1.5·2·4
1.2.1.2 Typography . ....... . ...... . . ... . .. ... . 19 Letterpress Printing Inks .. . ..... .. .. . . . . 139
1·5·2·5
1.2·1.3 Graphic Design .. .... .. . . . ... . ........ . 23 1.5.2.6 Screen Printing Inks .. . . ..... ... . . . .. .. . 139
1.2.2 Prepress . .. . .... . . .. . ... .. . . . . . . .. ... . 24 Pad Printing Inks . . . . .. . . .... . ...... . .. . 140
1·5·2·7
1.2·3 Printing . . ...... . ... . .. . . .. .... . . .. . . . 29 1.5·2.8 Inks for Non-Impact Printing
1.2-4 Postpress/Finishing . .. ... . . ... . . ...... . . 33 Technologies ...... . .. .. .. .... .... . . . . . 140
1.2·5 Digital Production Equipment Varn ishes ............. . .... . .. . . . . .. . . 142
1.5·3
in the Workflow .......... . ..... . ...... . 35
1.2.6 Premedia 38 1.6 Printing Pre e and Printing y terns 145
1.6.1 General Structure ............ . . . .. . ... . 145
1·3 Printing Technologies 40 1.6.2 Designs for Multicolor Printing . ....... . . . 15 0
1.3·1 Overview of Printing Technologies ....... . 40 1.6.2.1 Sheet-fed Printing Presses . . ..... . . ... .. . 150
1.3·2 Printing Technologies with 1.6.2.2 Web-fed Printing Presses ... . . ... . .. ... . . 154
a Printing Master ..... . ..... . .. .. .. . ... . 41 1.6.2.3 Packaging Printing Presses . . ... .. . . ..... . 159
1.3.2.1 Letterpress/Flexographic Printing . . .. .. .. . 45
1.3.2.2 Gravure Printing .. .. . ...... . ... . ..... . . 48 1·7 Drying Methods 166
1.3.2.3 Lithography/Offset Printing ... ..... . . .. . . 52 Physical Drying (Absorption) . .. . . . . . .. . . 166
1.7·1
1.3·2·4 Screen Printing ..... . ... .. . ... .. . .. .. . . 55 1.7·1.1 Infrared (IR) Drying . ........ . .. . .. .. .. . 169
1.3·3 Printing Technologies without Evaporative Drying .... . .. . . . .. . . . .. . .. . 170
1.7·1.2
a Master (NIP Technologies) .. .... ...... . 58 Problems in Practical Operation ... . .. .. . .
1.7·1.3 172
1.3·3·1 Electrophotography ..... . ... .... ...... . 60 Chemical Drying/Curing . . ... . ......... .
1.7·2 173
1.3.3.2 Ink Jet ..................... . ........ . 63 1.7·2.1 Oxidation .................. . .. .. ..... . 173
1.3·3·3 Printing Systems based on Non-Impact 1.7·2.2 UV Drying/Curing .......... .. . . . . . . . . 173
Printing Technologies ...... . . .. .. . ..... . Electron Beam Drying/Curing (EBC) ..... . 175
1.7·2·3
L7·3 Auxiliary Drying Techniques . . . . . .... . . . . 17 6
XIV Table of Contents

1.7·3·1 Powder Spraying . . ... ... . ............. . 2·1. 4·5 Tn-line Print Quality Measurement and
1.7·3·2 Silicone Application .. . . .. . . ........... . Control Systems ... ... ..... . .......... . 312
1.7·4 Measuring Techniques ................. . The State of the Art in Remote Control,
Measurement and Control Systems ....... . 317
1.8 Products of Print Finishing .......... .. . 180 2·1.5 Automation in Print Media Production ... . 319
2·1.5·1 Wash-up Procedures .... ...... ......... . 320
1.9 Aspects of Management and 2·1.5·2 Plate Changing ........ . .............. . 321
Business Models .... . . ..... . . .... . .. . . . 2·1.5·3 Sheet Size and Paper Travel Adjustment ... . 32 3
1·9·1 Production Options and Business 2·1.5-4 Ink Feed Presetting in the Printing Unit . .. . 32 5
Models . .. .. . ... .. .. . .... . ......... . . . 2·1.5·5 Ink and Dampening Solution Supply .. ... . 328
1.9·1.1 The Value-added Chain (Production 2·1.5·6 Makeready for Print Production . . . . . .... . 32 9
Depth and Product Range) ............. . 186 2.1.6 Examples of Offset Printing Presses and
)·9· 1.2 Financing and Distribution Models ...... . 188 Production Systems .. .. ... .. . ... . ...... . 333
1.9·1.3 Media Business as a Technical Service .... . 190 2.1.6.1 Sheet-fed Offset Printing Presses ........ . 333
1.9·2 Coordination of Work flows .. ........... . 190 2.1.6.2 Web-fed Offset Printing Presses/Systems .. . 338
1.9·2.1 Lean Production and Lean Management .. . 190 2·1.7 Potential for Further Development ....... . 354
1.9·2.2 Tracking ............ . ................ . 192 2.1.7.1 Print Quality ........... .. . .. ......... . 354
1.9·2·3 Quality Assurance ....... .. ............ . 195 2·1.7·2 Offset Printing Process .. . .............. . 355
1.9·3 Production Layout ... ... .............. . 197 2·I.7·3 Drying .......... . .. .... ............. . 356
1.9·3·1 Material Flow ........ .. . .. . .. ......... . 197 2·1.7-4 Automation ......... .... . . ... .. ...... . 357
1.9·3·2 Capacity Planning . .. . ..... .. .......... . 199
1.9·3·3 Personnel Deployment and Supply 2.2 Gravure Printing
of Utilities ......... ... . .. . ... ... .. .. . . 200 2.2.1 Process . . . . ........ .... ... .. .. . ... . .. .
2.2.1.1 Gravure Cylinder Manufacture . .... .. . .. .
2 Printing Technologies with Permanent 2.2.1.2 Gravure Cylinder Imagi ng . .. . .. .. ..... . .
Printing Master 2.2·1.3 Storage and Changing of Gravure
Cylinders ............. .... ........... . 366
2.1 Off el Printing ..... . ....... . ......... . 206 2.2.1.4 Impression Roller ...... . .. ... ......... . 36 8
2.1.1 Basic Principles ..... . .. . .............. . 206 2.2·1.5 Inking Unit and Doctor Blade ........... . 369
2.1.1.1 Process ........... ....... ............ . 206 2.2.1.6 Drying ............ ... . ... ........... . 372
2.1.1.2 Printing Plates, Printing Ink, Dampening 2.2·1.7 Circumferential and Lateral Register ..... . 37 2
Solution ...... . .. ... ......... . ....... . 209 2.2.1.8 Magazine Turner Bars Superstructure .... . 374
2.1. 1.3 Inking Unit, Dampening Unit, Printing 2.2·1.9 Gravure Printing Folders .. .. . ..... . .... . 374
Unit .. .. . ... ... . ... . . ... ... . . . .. . .. . . . 21 3 2.2.1.10 Reel Stand ........... .. ... ... . ... . .. . . 377
2·1.1.4 Print Quality .. . . . . . ... . .... ..... .... . . 223 2. 2.2 Examples of Gravure Printing Systems .. .. . 377
2.1.2 Sheet-fed Offset Printing ............... . 226 2.2·3 Gravure Printing in the Packaging
2.1..2.1 Paper Travel ........ . ........ ...... ... . 226 Industry . .... . .. . ... .... . . ... . ....... .
2.1.2.2 Feeders ...... . ...... . ................ . 229 2.2-4 Potential for Further Development
2.1.2·3 Printing Units . ... .. ...... ............ . 237
2.1.2·4 Sheet Reversal/Perfecting ... ............ . 244 2·3 Letterpr Printing 395
2.1.2·5 Delivery ............ . ............... . . 247 2·3·1 Basic Principles ...... . . .. ............. . 395
2.1.2.6 Drying ............ .. ................ . 251 2·3·2 Letterpress Printing (Process and
2.1.2·7 Print Enhancement and In-line Finishing .. 254 Applications) ...... ..... . . . . .......... . 396
2.1.2.8 Press Architecture (Special Designs) ...... . 257 2·3·3 Flexography ............. . ... . .... . ... . 397
2·1.3 Web-fed Offset Printing ................ . 260 2·3·3·1 Process ........ . ........ . . ..... ...... . 397
2·1.3·1 Press and System Concepts (Components) .. 260 2.3.3. 2 Printing Unit .. ...... . . . ....... . .. .. .. . 401
2·1.3·2 Web Travel (Infecd and Further 2·3·3·3 Examples of Flexographic Printing
Processing) ....... .. .. .. . . .. . .... ... . . . 276 Presses . ....... . .. .. .... .. .. .... .... . . 404
2·1.3·3 Printing Unit ......... ..... . ..... . .. . . . 281 2·3·4 Potential for Further Development 40 7
2·1.3-4 Folders and Print Product Variations . .... . 286
2·1.3 ·5 Newspaper Printing ...... ............ . . 292 2·4 crcen Printing 409
2·1.4 Remote Control, Measurement and 2-4.1 Basic Principles/Process . .. .. . . ......... . 409
Control Technology/Systems ........... . . 297 2-4-1.1 Platemaking .......... . ............... . 410
2·1.4·1 Press Remote Control Systems ........... . 298 2·4·1.2 Printing Process .... . .................. . 414
2·1.4·2 Color Measurement and Control Systems " 300 2-4.2 Applications .......... . ......... . . . ... . 4 16
2·1.4·3 Register Measurement and Control ...... . 307 2.4.2 .1 Screen Printing on Flat Surfaces . .. . ..... . 416
2·1.4-4 Inspection of the Printed Image . .... . ... . 30 8 2.4.2.2 Screen Printing on Curved Surfaces ...... . 417
 Table of Contents XV

2-4·3 Examples of Machinery . .. .... . . ....... . 3·1.7·3 Letterpress Printing, Flexography .... .... . 497
2-4·3·1 Equipment and Machinery for Flat-bed 3·1.7-4 Gravure Printing .......... ...... .. . ... . 498
Screen Printing ............ . .......... . 417 3·1.7·5 Screen Printing ........... ...... .. . .. . . 49 8
Screen Printing Machinery for Printing 3·1.8 Color Management ....... ... . .. ....... . 499
on Curved Surfaces ......... .. . . ....... . 418 3·1.8.1 Processes for the Correction of Tone Values
2·4·3·3 Rotary Screen Printing Presses . ......... . 418 and Color Values ......... ... ...... .. .. . 500
2-4·4 Potential for Further Development 422 3·1.8.2 Offset-Gravure Conversion .. . ...... .... . 50 1

2·5 pedal Printing Technologie and 3·2 Digital Prepress .. ... . . . . . . ... . . ... ... . . 503
Product Specific Application ... ... . ... . . 423 3·2.1 Structure of Digital Printed Products . .. .. . 503
2·5·1 Security Printing ... .. . . .. .. . . ....... .. . 423 3·2.1.1 Technological Capabilities and
2·5·1 .1 Bank Notes ......... . .... . .. .... .. .. . . . 423 Workflows ..... .. ...... . .... .. ....... . 503
2·5·1.2 Postage Stamps, Stamps . . .... . ....... . . . 429 3·2.1.2 Digital Description of the Printed Page ... . 505
2·5·1.3 Documents .......... . .. .. . ...... ..... . 432 3·2·1.3 Digital Screening Processes .. .... ....... . 50 8
2·5·2 Business Forms Printing ..... ...... ..... . 433 3·2.2 Quality Requirements .... ........... ... . 513
2·5·3 Label Printing ......... ...... ......... . 438 3·2.2.1 Input and Output Resolution ... . ....... . 51 4
2·5-4 Pad Transfer Printing ......... .. ....... . 442 3·2.2.2 Transferable Tonal Range .... . .. . . . ..... . 516
2·5·4·1 Printing Process ............ ... ........ . 443 3·2.2·3 Dot Shape ...................... .. ... . 517
2.5.4. 2 Cliche Making ........ ............ .... . 445 3·2.2·4 Tone Value Influences in Printing ..... ... . 518
2·5-4·3 Pad, Ink, Object Holding Device . . ...... . 447 3.2.2.5 Color Management Profiles ... . . .... . ... . 51 9
2·5·4-4 Multicolor Pad Transfer Printing, 3.2.2.6 Image-dependent Effects and Corrections . . 51 9
Applications ... .. . ....... ... . ......... . 447 3·2·3 Digital Photography ........ ...... ..... . 520
3.2.3. 1 Origins of Digital Photography .... . .. . .. . 5 20
3.2.3. 2 Image Scanning with Digital Cameras .. . . . 52 1
3 Prepress
3·2·3·3 Demands on the Resolution . . . ..... . . . .. . 52 3
3. 1 Conventional Prepress . ... .... .. . . ... . • . 452 3·2·3-4 Special Features of Digital Cameras ...... . 524
3·1.1 Word Processing, Typesetting .. ......... . 453 3. 2 .3.5 Digital Photography and
3·1.1.1 Typesetting Procedure ...... .......... . . 453 Color Management ........ . ...... ... .. . 52 5
3·1.1.2 Manuscript ............ . . . .. ... ....... . 454 3·2·4 Digitizing Originals (Scanner) ........... . 52 5
3·1.1.3 Text Input .............. ......... ..... . 454 3·2·4·1 Scanner Designs and Models .... . ..... .. . 52 6
3·1.1.4 Word Processing and Typesetting ........ . 456 3.2-4.2 Drum Scanners ............... . ...... . . 52 9
3·1.2 Text Output for the Production 3·2-4·3 Flat-bed Scanners ....... ...... .... ... . . 529
of Film/Plate .. . . ... . ....... .... ...... . 3·2·4-4 Digitizing and Redigitizing . . ... .. .... .. . 531
3·1.2.1 Designs of Output Devices . .... . .. ... ... . 3·2·5 Sheet Assembly and Imposition . . .. . . .... . 532
3·1.2.2 Requirements on Films .... . .. .. .. .. ... . 3·2·5·1 Page Make-up and Sheet Assembly .... . . . . 533
3·1.3 Photomechanical Image Processing/ 3.2.5.2 Full-Sheet Output . .. . . . ... ... .. ..... . . . 533
Reproduction ............ ... . . . . ...... . 3·2·5·3 Imposition through Software . . .... ..... . 534
3·1.3·1 Use and Importance of Analog 3·2·5-4 imposition Workflows ...... . . .... .. .. . . 537
Reproduction ......... ..... .. . ... .. ... . 3.2.6 Raster Image Processor (RIP) . .. .... .. .. . 540
3·1.3·2 Principles, Tasks of Photo mechanical 3·2·7 Storage Media .............. ... .. . .... . 545
Reproduction ............ . ... ... ...... . 3·2.8 Networks ................. .. .. .. ... . . . 547
3·1.3·3 Materials ............... ....... ....... . 3. 2 .8.1 Network Concepts and Components .. . .. . 547
3·1.3-4 Machines and Devices used in 3·2.8.2 Working with Networks ... .. . . . ... .... . 549
Reproduction Technology .... .. ........ . 3·2·9 Data Formats .......... ............... . 550
3·1.3·5 Production of Film Copies for 3·2.10 Color Management .......... .. . . . .. .. . . 555
Single-Color Printing .. .... ...... .. . ... . 474 3·2.10.1 The Image Reproduction Process
3·1.3·6 Production of Film Copies for Multicolor using Color Management ..... . . .... . ... . 555
Printing .. .... .. . . . .. .... .. ..... ..... . 479 3·2.10.2 Production of Color Profiles ... .... . .... . 555
3·1-4 Electronic Reproduction Technology 3·2.10·3 Structure of Color Profiles .... . . . .. . . .. . . 557
(Repro Scanner) ........ ... . . ......... . 3·2.10·4 Connection of Color Profiles .. ... . ...... . 558
3·1.5 Assembly ............ .. ... .... . ... ... . 3·2.10·5 Rendering Intent ........ . . . . ... . . .. ... . 560
3·1.5·1 Page Make-up .......... . . ...... .. .. .. . 3.2.10.6 Color Management and the
3.1.5.2 Sheet Assembly ........... ....... ..... . Production of Proofs .......... . ... .. .. .
3·1.6 Proofs/Test Print ............ . ... . ..... . 3. 2 . 10.7 Color Management for Images
3·1.7 Platemaking and Quality Control ........ . on the Internet ............ .... .. ...... .
3·1.7·1 General Information ... ...... . ... ...... . 3·2.10.8 Color Management and Standardization .,.
3·1.7·2 Offset Printing ......... .... .......... . 3. 2 .11 Digital Proof .......... . .. ... . .. ..... . .
XVI Tab le of Contents

3.2.11 .1 Digital Proofing Processes . .. .. . ...... . . . 563 4.4.2.1 Concepts for Re-i mageable Masters with
3·2.11.2 oft Proof . .. ... . .... .. ... .. .. . .. .. . . . . 563 Material Appl ication/Ablation. . . . . . . . . . 643
..
3·2.11·3 Hard Proof ...................... . .... . 563 4-4-2.2 Re-imageable PrintirIg Plate System
3·2.ll·4 Color Management Concepts ... .... . ... . 566 without Material Application. . . . . . . . ... . .652
3·2.11·5 Preflight Check ... . ... . .. .. ........ ... . 570
3·2.1 2 Film Production and Platemaking .. • ..... 570 4·5 Computer to Print .... . .. . .... . . . . . .... 657
3·2.12.1 Computer to Film ystem .... . ... ..... . . 570 4·5·1 Printing Systems ba ed on
3·2.12.2 Computer to Plate Systems .. ... . . ...... . 573 Electropbotography . . ........ . ... .. .... 658
3·2.12·3 Computer to FUm and Computer to Plate Printing Systems based on Ionography,
in the Prepress Workflow . . . ...... ... ... . 573 Magnetograpby, and Ink Jet. . . . . . . . . ... . 664 .
4·5·3 Design Principles of Computer to Print
Systems . . . . . . . . . . . . . . . . . . . . ... . 665
. ... . .
4 Computer to . . . Technologies Digital Printing . . . . . . . . . . . . . . . ... . .672
. . . .
4·5·4
4 .1 urvey of the Technologies . . •.. . ........
4·1.1 Computer to Film ........... .. ... .... . .
4·1 .2 Com puter to Plate .. . .. . .. .. . . ... .. ... . . 5 Printing Technologies w ithout a Printing
Computer to Press (Direct Imaging and Plate (NIP Technologies)
4·1.3
Computer to Print) ... ..... ... . ...... . . . 5· L Principles and Bas ic Components ....... . 677
The Use of Computer to ... Techno logies 5·l.1 Computer to Press!to Print Technology. . .. 677
and Networking for the Production 5·1.2 Non - Impact Printing Technologies
of Print Media . ... .. ... . . . .... . . . ..... . 588 (Overview) .... . . .. ..... . . .. ....... .... 678
5·l.3 Printing Process and Functional
Computer to Film . ........ . .. . ........ . 593 Components in NIP Technologies ........ 679
Principl es and Equipment .... .......... . 593 5·1.4 Digitally Controlled Image Creation
Film Material .. . .. . . .. . ... . . . . ........ . 594 in NIP Technologie .. .. ... .. ........... 679
5. 1 .5 ystem Co ncepts/A rchitecture of
4·3 Comp uter to Plate/to Cylinder/to Screen . . 597 Computer to Print ystems . . ........ . . . . 681
4·3·1 Introductio n . ........... . ............ . 597 5·1.6 Inks for on -Impact Printing
4.3. 2 Technology o f Computer to Plate Processes. . . . . . . . . . . . . . . . . . . . ... . .685. . . . .
ystems for Offset Printing . . ........... . 598 Components for Computer to Print
4·3·2.1 Design Principle ........ . .. .......... . . 598 Systems . . . . . . . . . . . . . . . . . . . . ... . .687.....
4·3·2.2 Lmaging Methods and Plate Punching . . .. . 601
4·3·2·3 Computer to Plate Systems for Offse t 5. 2 Electrophotography ................... . 689
Printing ....... .. ... . .. . ...... ....... . 5. 2 .1 Principle of Electrophotography . . . . . .... . 689
4·3·3 Computer to Plate for Flexographic 5·2.2 Imaging Systems. . . . . . . . . . . . . . . . . .691 .. . . .
Printing . ......... . ...... . .......... . . 608 5·2·3 Inking Unit (Developing Unit)
4·3·4 Computer to Cylinder for and Toner. . . . . . . . . . . . . . . . . . . ... . 692
. . . . . .
Gravure Printing ..................... . . 611 5. 2 -4 Fixing and Clean ing .................. . . 696
4·3·5 Computer to Screen fo r Screen Printing . . . 611 5. 2 ., Conception of the Printing Unit. . . . . . .... 698
4 ·3·6 Computer to Plate Workflow ... . ...... .. . 6u
4·3·7 Rise in Quality as a Result of Com pUler 5·3 lonography . . . . . . . . . . . . . . . . . . . . 701
. .. ....
to Plate . .... . .................. ... .. . 614 5·3·1 Printing Unit . . . . . . . . . . . . . . . . . . . . 701
. ....
4·3·8 Productivity and Economic Efficiency .... . 615 5.3. 2 imaging System a nd the Principle
4·3·9 Printing Plates fo r Digital Imaging ... .. .. . 616 oflonography .... ..... ......... .. .. . .. 702
4·3·10 Trends in Computer to Plate ...... ... ... . 62 3 5·3·3 Printing Unit Concepts and Printing
Systems based on lonography ...... . ..... 703
4·4 Computer to Press/Direct Imaging ...... .
4·4·1 Computer to Press/Direct Imaging 5·4 Magnctography . . . . . . . . . . . . . . . .. . . .706
. . . .
with Removal of the Master for each 5-4·1 Principle of Magnetography .... .... ..... 706
Print Job .. . . .. . . .... . ...... .. ... . . ... . 628 5-4. 2 Imaging System for Magnetography . . . .... 708
Computer to Press/Direct Imaging 5·4·3 Example of Application !Printing
Printing ystem ..... . . . .... .. ..... .. . . Systems . . . . . . . . . . . . . . . . . . . . ..
. . 709
. . .. ..
Expa nsion and Com parison of Systems
Computer to Press/Direct Imaging 5·5 InkJet ........................ . . . ... .. 711
Printing Systems with Re-imageable 5.5. 1 Overview of Ink Jet Technologies
Master ... ........... . ...... .... ..... . . and Processes. . . . . . . . . . . . . . . . . . . . 71]
. . . . .
 Table of Contents XVII

5·5·2 Continuous Ink Jet .................... . 714 7·2.1 Cutting and Die-Cutting ............... .
5·5·3 Drop on Demand Ink Jet Technologies ... . 71; 7·2.1.1 Characterization of the Processes ........ .
5·5-4 tructure of 1nk Jet Arrays .............. . 7 23 7. 2.1.2 Cutting with Guillotine Cutter .... .. .... .
5·5·5 Printing System ba ed on Lnk Jet 7.2.1.3 ulting Webs ......................... .
Technology for Multicolor Printing 7·2·1.4 Die-Cutting ........ . ..... ... ......... .
(Selection) ........................... . 725 7·2.2 Folding . . ..... .. .. .. . . .... ...... ..... .
7·2.2.1 Characterization of the Process ......... .
5·6 Thermography ... .......... .......... . 731 7. 2. 2 . 2 Folding with Folding Machines .......... .
;.6.1 Overview of Thermography 7·2.2·3 Folding Bookbinding Sheets ............ .
Technologie ................ . ........ . 731 7. 2 .3 Forwarding ............. . ............. .
5·6.2 Thermal Transfer Printing y terns ....... . 734 7. 2 .3. 1 Characterization of the Process .......... .
5. 6 .3 Therma l Sublimation Printing Systems ... . 738 7·2·3·2 Forwarding Proces in Industrial
Finishing ............................ . 812
5·7 Electrography ... ... ............ ....... . 742 7·2·4 Assembling into Blocks ................. . 816
7.2-4.1 Characterization of the Proce ......... . 816
5.8 Photography ...... ........ ... .... .... . 7. 2 -4- 2 athering .... . ....................... . 816
7. 2 -4-3 athering into Single-layer Blocks ....... . 821
5·9 .. "-Graphy ........... .. ............. . 749 Binding Blocks ........................ .
7-2·5 82 5
5·9·1 Toner/et Printing Technology ........... . 750 Characterization of the Process ..... ..... . 825
7. 2 .5. 1
5·9·2 Ekography ... ..... ....... ........... . . 752 7.2.5. 2 Thread-Stitching Books . . ....... ... .... . 826
5·9·3 Direct Imaging Printing Technology ...... . 754 Perfect Binding ........... .... •........
7. 2 .5.3 83 0
;·9-4 As essment of ew Types of Thread-Sealing .. . .. ........ . ......... .
7. 2 .5-4 837
NIP Technologies ..................... . Wire-Stitching . ...... .... ..... ........ .
7·2·5·5 839
7.2.6 Trimming . .. ... . ... .. ... ........ . .... . 84 2
7. 2 . 6 . 1 Characterization of the Process ... ....... . 84 2
6 Hybrid Printing Systems Trimming Book Blocks and Brochures .... . 842
7·2.6.2
6.1 Overview of Print ing Methods and 7. 2 .7 Edge Treatments on Books and
Technologie ......................... . 761 Brochures ....... ... ............. ... .. .
7·2·7·1 Characterization of the Process ..... . ... .
6.2 Combination Variants of Hybrid Printing 7. 2 .7. 2 Process Sections of Block Edge
Systems ................. ............ . . Treatments ........................... .
7.2.8 Case Making ................ . ........ .
System Concept and Examples of 7.2.8.] Characterization of the Process ... ... .... .
Implementation ...................... . 7·2.8.2 Producing Book Covers .......... ...... .
6·3·1 Hybrid Printing Systems combining 7·2·9 Book Finishing ....................... .
Conventional Printing Technologies ...... . 7·2·9·1 Characterization of the Process ....... ... .
6.3. 2 Hybrid Printing y tern combining 7·2·9· 2 The Process Sections of Book Finishing ... .
1P Technologies ..................... . 7·2.10 Packaging ..................... ..... .. .
6·3·3 Hybrid Printing System combining 7. 2 .10.1 haracterization of the Process .. . .... . .. .
Conventional and IP Technologies . ... . . . 76 6 7. 2 .10.2 Packaging of Books and Brochures ....... .
6·3·4 Hybrid Printing Systems combining
Computer to Press/Direct Imaging 7·3 Proces tructuring in Print Fini hing .... . 862
with IP Technologies ................. . 7·3·1 Ba ic Principles of Proce s Structuring .... . 862
6·3·5 Hybrid Printing Systems combining 7·3·1.1 Production Plow in Print Finishing ...... . 862
Conventional Printing Technologies 7·3·1.2 Interlinking Module in Print Finishing ... . 863
with Computer to Press Technologies . .. .. . 7·3·1.3 Tern porary Storage of Folded Sheets ...... . 867
7·3·2 Production Line in Print Fini rung
Hybrid Technique for Ln-line and Off-line (Examples) ................ .. . ........ .
Print Production ...................... . 77] 7·3·2.1 Cutting Lines for Labels ................ .
7·3·2.2 Production Lines for Mailing and Folded
Products ............................. .
7 Print Finishing Processes
7·3·2·3 New 'paper Mailroom .. ... . .... . . ...... .
7. 1 las ification of Print Fini hing 7·3·2·4 Mailroom for Magazine .. ... ...... . . . . .
Proccsse ... ..... .............. ...... . 775 7·3·2·5 Binding Lines for MuLti-layer
Brochures ............................ . 886
7·2 Process Step and Procedure for 7·3·2.6 Production Lines for Hardcovers ........ . 887
Print Finish ing ....................... . 7·3·2·7 Finishing Short Print Runs ............. . 89 1
XVIII Table of Contents

7·3·2.8 Bag Production ystem . .. ... . ..... . ... . 894 10 Comparison of Printing and Producti on
7.3.2.9 Folding Boxes. . . . . . . . . . . . . . . . . . . . 897
... . .. Technologies fo r Print Media

10.1 Introduction ........ . ........ . . ... . .. .

8 Material and Data Fl ow
in Print Media Production 10.2 Overview of Methods and Technologies
for th e Production of Print Media ... .. . . .
8.1 Material Logistics ..... . .... .. .... . ... .. 905
8.1.1 Logistics around the Pres . . .. .... ..... . . 905
8.1.1.1 Supply of Printing Plates . .. . ... ... .. . . . . 906 10·3 Production Methods and Strategies ... . .. .
8.1.1.2 Paper Reel Logistics. . . . . . . . . . . . . . . . 908 . .. ..
8.1.1 ·3 Ink, Dampening Solution, and Criteria for the Selection of Prin ting
Air Supply . ..... . . . ........ . .......... 910 Technologies and Production Methods ... . 973
8·1.1.4 Waste Disposal. . . . . . . . . . . . . . . . . . . 911. . ....
8·1.1·5 Paper Pile Logi tics for Sheet-fed 10·5 Performan ce Criteria of Printing Systems
Offset Presses . . . . . . . . . . . . . . . . . . . 911 . .. . . . . and Trends in Print Media Production .. . . 975
8.1.2 Logistics in Prin ting Companjes . . . .. . . . . . 914 10.5-\ Quality and Productivity/ Run Length .... . 975
8.1.2.1 Procurement Logi tics in Printing 10·5·2 Productivity ........................ . . . 976
Companies . . . . . . . . . . . . . . . . . . . . .915. . . . 10·5·3
. . . Production Co ts per Printed Page .... . .. . 976
8.1.2.2 Inventory Management in Printing 10·5·4 Trends in Print Merua Production . . ..... . 978
Companies . . . . . . . . . . . . . . . . . . . . .917.. .. .. .
8.1 .2·3 Production Logi tics in Printing
Companies. . . . . . . ..... . . ..... . . . .11
. . 918 . . . Electronic Medi a and Multimedia
8.1·3 Logistics in Publishing Houses . . .. ... ... . 920
11.1 Merua Concepts ..... . . .. ..... . . . ..... .
8.2 Networking and Data Flow .... . . . . . . . . .923 .
8.2.1 etwork Concepts and Interfaces. . . . . . .. . 924
11.2 Data Types. Data Structures and their
8.2.2 Digital Workflow. . . . . . . . . . . . . . .... . .926 ...
Applications ................... . ...... .
8.2.2.1 Digital Workflow in Prepress . . . . . . . . . . 926 . ..
11.2.1 Text ..................... . .. .. .... .. .
8.2.2.2 Digital Workflow and Digital
11.2.2 Graphics .. . ......... . .... . . . . . ....... .
Printing (Computer to Pres ) . ...... . .. . . 928
11 .2·3 Image . . ............ . ..... . .... .... . . .
8.2.2·3 Digital Workflow: Advantage, Challenges,
11.2·4 Audio . . .. . ..... .. . . .... . .......... . . .
and Possibilities. . . . . . . . . . . . . . . .... . 929
. ...
11.2·5 Video .. . .......... . .... . .... . .. . . . . . .
8.2·3 CIP3 for the Computer-Integrated
11.2.6 An.imation .............. . ... . ..... . .. .
Manufacturing (CIM ) of Printed
Virtual Reality (VR) ......... . ...... . .. .
. . . . 11.2·7
Products . . . . . . . . . . . . . . . . . . . ... . .930 . .
11.2.8 Augmented ReaLity . . .... . . . . ... . . .. . .. .
8.2-4 Production Management/Monitoring
1l.2·9 Multimedia ........ . .... . ... . .. ..... . .
System ............. . ................. 934
11.2.10 Document . .. . . . . ... ... ....... ..... .. .
Purpose, Applications. . . . . . . . . . . . ... . .934 . .
Production Monitoring Systems .......... 935
11·3 Dat a Carrier .......... . ........... .. . . 993
ll ·3·1 Hard Disk Storage Units . ......... . ... . . . 993
11·3·2 Rewritable, Removable Storage Units ..... . 993
9 Production Strategies for Print Media CD-ROM and DVD- ROM ..... . ....... . .
11.3·3 993
Production Concepts .... . ... ..... .. .. . . 939 11.3·4 Magnetic Tapes .. . . .... .. . . ........... . 994
Strategic Orientation of
Printing Companies ......... . ...... . .. . 939 11·4 Networks ........... . ... . .... . ... . .. . . 995
Centralized and Distributed 11.4·1 Internet ..... . ........ . ...... . . . ..... . 995
Production . . . . . . . . . . . . . . . . . . . . . . . . .J1.4·2
941 .. . [ntranet, Extranet ... . ................. . 996
9·1.2.1 Centralized Production at One Site ... . ... 941 11.4·3 Broad Band etworks . .. . ...... . . . .... . . 99 6
9·1.2.2 Distributed Production at Severa.1Sites . . . . 943
9·1.2·3 Integrated Production , Interlinking 11·5 Data Compression ... .. . ..... . ........ . 998
of Systems .. . . . ........ . ..... . ... . .... 944 11.5. 1 Compressed Data Archives .... .. . . .. . ... . 998
Print on Demand . . .. . ........ . . .. ..... 945 11·5·2 Compression Processes for Image
Personalization ..... ....... .. . . ........ 948 Data Files . . . ...... . ............ ...... . 998
11·5·3 Compression Processes for Audio . ..... .. . 999
Production Sy tem s ......... . . . . ... . . .. 952 1l·5·4 Compres iOIl Processes for Video .... . .. . . 999
 Table of Contents
XIX

11.6 Output Devices for Electronic Media 13·2 Environment, Safety, Standardizat ion .. ...
and Multimedia . . . . . . . . . . . . . . . . . . 1001
.... ..
13·2.1 Environmental Protection in the Printing
11.6.1 creen Output ........ . . . . . . . . . . . ... .1001 . . Industry .... ....... .. .. ... .. ... ..... . .
11.6.2 Projection Equipment. . . . . . . . . . . . ... . 1002
.. . 13·2.L1 Introduction . ........................ .
11.6·3 Stereo Output . ... ...... ...... .... ..... 1002 13·2.1.2 Environmental Protection in Offset
H.6-4 Projection Directly to the Eyes . . . . . . . ... . .1003 Prin ting .... ............... ... ..... .. .
13·2·1.3 Environmental Protection in Gravure
11.7 Multimedia Applications ................ 1004 Printil1g ..... ... ...... . . ... ... ..... .. . 1079
13·2.1·4 Environmental Protection in Letterpress
and Flexographic Printing ... ... ..... ... . 1080
12 Print Media and Electronic Media 13·2.1·5 Environmental Protection in Screen
Printing ............................. . l080
12.1 Examples of Print Media and 13·2 . t.6 Environment-oriented Business
Electronic Med ia. . . . . . . . . . . . . . . . .. .1007
... . Management ...... .... .... ........... . 1080
13. 2 .1.7 Legal Foundations ..................... . 1.081
12.2 The Prod uction of Print Media and 13·2.1.8 Support and Advice for Environment-
Electronic Medja . . . . . . . . . . . . . . .... .1010
.. .. relevrult Mea ure ............. .. ...... .
13·2.2 Safety Resources ............... . ..... . .
12·3 "Electronic" Books, "Electronic" Ink, 13·2.2. 1 Health and Safety .................. . .. .
"Electro nic" Paper . ..... .. ..... .. . ... . . 1013 13. 2 .2 .2 In ternatio nal and European
12·3·1 "Electronic" Books (E-Books) . .. ..... .... 1013 Directives (Laws) and tandards ... .. .... . 10 85
12·3·2 "Electronic" Ink (E-Ink), 13·2.2·3 Safety-conscious Design .. . . . .. ...... . .. . \086
"Electronic" Paper (E- Paper) . . . . . . . . ... . lOJ5
. 13·2.2·4 Requirements for Separating Protective
Devices ... . ......... .... ..... ... . .... . 1089
Market Shares and Trends . . . . . . . . . ... . 1020
. . 13·2.2·5 Hazard Analysis, Risk Assessment ....... . . 1091
13.2 . 2.6 CE and GS Marks of Conformity ........ . 1091
13· 2 .2·7 Intended Use .... ... ... ..... ... ....... . 1093
13 Special Topics 13··2 ·3 Industry tandards, Codes of Practice
and NationallLnternational Standards ..... 1093
13·1 History, Education, Research ...... .... .. 1029
13·1.1 History of Technology Markets and Development Trend for
13·3
(Pre sand Prepre s) .......... . ......... 1029
Print Media ...... .. ...... .. ... . .. .. .. . 1102
13·1.1.1 Offset Printing and Offset
13·3 ·1 Newspaper Market ..... . ...... ...... .. . 1102
Printing Presses . . . . . . . . . . . . . . . ... . . 1029
. .. .
13·3 ·2 Magazine Ma rket ........ ...... .. ..... . . 1105
13·l.l · 2 Gravure Printing and Gravure
13·3·3 Book Market . . . . ..................... . 1106
Printing Presses .......... _ . . . . . . . . . .1032 . ..
13·3·4 Catalog Market .. . ... . .... ... . ....... . . 1107
13·).1.3 Letterpress Printing and Letterpress
13·3·5 Advertising Printing Market ............ . 1107
Printing Pre ses . . . . . . . . . . . . . . . .... 1034
. .. . .
13·3·6 Packaging Market ..................... . 1108
13·1.1.4 The Historical Relationsh ip of the
13·3·7 SOHO Market ... . . .. ..•............... 1108
Printing Press Manufactu rers ......... ... 1041
13·1.1. 5 Prepress .. ..... .... . ..... ... .. .. .... . . 1043
13·1.2 Education and Qualifications
(Career Profiles, ourses)................ 1048 14 Appendix
13·1.2.1 The Printing Industry as an Employer .. . .. 1048
13·1.2.2 Educational Requirement and Options. . . . 1049 14·1 Explanatio n of Specific Terms .. . ... .. .. . . illS
13·1.2·3 Vocational Training .... ........... __ . . . . 1050 14.1 . 1 Glossary .... ... ...................... . 1115
13·1.2·4 Course of Study. . . . . . . . . . . . . . . .... . 1052
... . 14·1.2 Abbreviations an d their Meaning
13·1.2·5 cholar hip for International (Selection) . ... .. . .. .. ... ........... _.. 1125
tudy Programs ..... ..... ....... .. .... , 1056 Abbrevia tions for Source References
13·1.2 .6 Hejdelberg Print Media Academy ......... 1057 Information .. .... ..... . . .. ... ........ . 1128
13·1.3 Science and Researcb
(selected Examples) . . . . . . . . . . . . . ... . 1059. .. . Physical/Technkal Quantities
13·1.3·1 ubject , Methods, and Cooperations. . . .. . 1059 and Conversion .. .... .. ....... ..... .. . 1130
13·1.3·2 Inking Units ................. ..... .. ... 1060 Quantities and Units in the SI- ystem
13.1.3.3 Printing Units ....................... . . 1063 (Selection) ... ........................ . 1130
13·1·3-4 beet Transfer ......................... 1067 14·2.2 Conversion between the SI-System and the
13·1·3·5 Industrial Joint Research ... ....... . ..... 1070 Imperial System (Metricnmperial) .. . . . .. . 1133
xx Table o fContents

14·3 Bibl iography ... ....... ... . . .... .. ... .. 1134 14·5 Research Associations and Educational
14·3·1 List of References to Readings on the In titution for the Graphic Arts rndu try
Chapters and Sections in this Handbook . .. 1134 (Selection) ............................ 1145
14·3·2 Selected Literature on Print Media related Universities ............ . . .. ........... 1145
Topics (General Bibliography and Research Institutes and Research
Individual Topics) . . . . . . . . . . . . . . ..
. . 1135
. .. . Centers ... . . . . . . . . . . . . . . . . . . . . .. . . ....
1147
14·5·3 Institutions for Teachi.nglTraining
14·4 Standard (Selection) . . .. . ......... . .... 1137 and Education ... . ..................... 1150
14·4·1 Prepress ..................... . .. . ..... 1137
14.4·2 Printing Inks ..... . . . ..... . . .. . ..... .. . 1138 Associations and Organization in the
14·4·3 Substrates. . . . . . . . . . . . . . . . . . .... . 1139
.. .... Printing and Publish ing Industry
14-4-4 Materials (Printing Plates, Blankets) . . . . ... U40 ( election) .... . . . .... . ....... ........ . 1153
14-4·5 Printing Technologies and Printing Associations and Organizations. . . . . . .... . 1153
Presses . .. . . ......... . . ..... ... .. . .. .. 1140 Industrial Joint Research ................ 1166
Finishing ....... ..... . . ....... .. . ..... 1141
Quality, Quality Specifications. and 14·7 International Conferences for the
Measurement Techniques. . . . . . . . . . ... . 1141 . . Graphic Arts Industry (Selection) 1168
Safety of Machinery ......... . ..... .. .. . 1143
Environmental Management. . . . . . . . ... . 1143 . 15 Subject Index .... . . . . . .. .. .... . . ..... 1173