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FLEXO Magazine : July 2011
consensus may be Cyan, Magenta, Yellow, Black, Orange, Green, and Violet (CMYKOGV). Next, a press must be outfitted with additional process anilox rolls. Optimizing the colors beyond CMYK will require collaboration with ink and roll manufacturers. Finally, profile tests need to be designed and run. The ink set chosen and the proof method selected will affect the test form to be used. The prepress challenge is to select builds to reproduce spot colors accurately and to manage those matches through prepress and proofing, rather than providing the printer a single plate and color target for each. In some designs, spot colors are overprinted with the intent of creating a third color. (See Figure 1). The flexo printer does not have much control over the resulting combination. Using ECG, the separator can predetermine that the resulting third color will match the design intent. Design for ECG flexo, however, has few limitations. An ECG printer may find that some spot colors, notably metallics, some pastels and certain high chroma colors will require spe- cial solutions if required. Beyond that, many other traditional flexo norms are overturned. DEIGN FREEDOM Since ECG printing uses a single ink set like CMYKOGV to build every color, there need be no limit to the number of spot colors in a design. In the Zeleznik research, using CMYKOGV placed nearly 90 percent of Pantone colors within reach of match. Since the approach uses all fine line anilox rolls every image, continuous tone or vector, may contain screen effects and fades. With the best screening and platemaking tech- niques, colors may come and go, appearing wherever they are needed and dropping out where they would add only un- wanted weight or grayness. The result is very vibrant, clean, rich color. With the improved fit and registration required to adopt the process, and with the common inks used for all colors, trapping rules change. Unwanted and apparent color-to-color overlap is reduced to a negligible, if any, concern. You can show a yellow burst against a blue sky without creating a green outline. You can also place a picture into a background without changing the shape or subtlety of the edges of the image. (Figure 2). ECG opens up the potential for a package design to fea- ture renditions of other packages in a line of products without Figure 1: When a 347 Green box overprints a 300 blue box, a third color is created. Using spot inks, the result is determined for you. Using ECG, the separator can predetermine that the resulting third color will match, but must first determine the design intent. www.flexography.org JUly 2011 FLEXO 43