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FLEXO Magazine : September 2010
Technologies & Techniques asahikasei_flexo_out_kd.pdf 1 4/10/10 12:03 AM to help them print better and save ink, you are spending five hours of prepress time a day, or 1,040 hours a year. (Multiply this by your hourly rate of prepress labor and you will see a major profit drain.) Color can be more accurate and predictable with this new optimization software. 2. Ink Savings: For every $1 million your company is spending on ink each year, let’s say only 25 percent of the ink is process color. The above example of 21 percent ink reduction has the potential of saving up to $52,500 per year. This is pure profits—like finding money dripping off an over-saturated press sheet. 3. Improved Accuracy: Image optimization will produce optimized press control while insuring color is correct. We have been seeing setup times on pressruns drop as much as 25 percent due to image optimization. The finan- cial return on reducing setup times by 25 percent is a lot more than $52,500 per year in most printing facilities. In ConClusIon I have purposely not named image optimization systems. I do not want this article to be an advertisement for any particu- lar software or system. I feel I have explained the difference. If the software just links to a higher level of GCR to make prints run better and save ink, it is ink optimization. If the software colorimetrically converts files with color accuracy as the primary goal and neutral color is removed where possible, this is “Image Optimization” Software and you will be amazed with the results. n ABOUT THE AUTHOR: Mike Ruff has been in the graphic printing industry for more than 39 years and is a member of the Academy of Screen Print Technology (ASPT). Ruff was trained at RIT in flexography and color management and is a G7 Expert. His is currently the chief technology officer of Nazdar Consulting Services of Shawnee, KS, and is actively involved in the implementation of screen, flexo and digital profitability improvement systems for some of the largest screen, flexo and digital print- ers in the U.S., Canada, Mexico and South and Central America. Ruff has authored numerous articles in trade publications domestically and internationally. Many of his articles have been translated to foreign languages and published worldwide. He is a two time winner of the prestigious Swormstedt Award given for the best tech- nical article of the year by the Academy of Screen Print Technology. FIgure 4. 68 FLeXO september 2010 www.flexography.org Original CMYK Image Hvy GCR CMYK Image Optimized Image 3 Color Down Comparison Notice that even though optimization saved ink... it added color to be more accurate to the RGB Original Notice the color shift on the Hvy GCR Nice pure gradient! Dress is blue... not purple Dress is Shifting to purple Light GCR Shifting gradient FLX_Sept2010_mech.indd 68 8/31/10 5:42 PM