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Hunan Tianwen's Use of Ink Presets
2. Application on Rotary Presses
The Key to Successful Ink Preset Implementation
Ink presets for efficient printing production
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The use of CIP3 ink preset technology has become quite common in the printing industry. This technology helps printing operators avoid inconsistencies caused by manual ink dispensing, save time during the ink setup process, and achieve efficient and high-quality printing. The ink data required for pre-setting is provided by a PPF file compliant with the CIP3 standard, generated during the pre-press stage. This data is then directly or via interface software used by the press to prepare ink before printing.
1. Application on Sheetfed Presses
Hunan Tianwen began using CIP3 ink presets back in 2001 when we introduced our first CTP equipment. At that time, our pre-press operations were still in their early stages, and we used the Brisque imposition process. We produced standard output files that met CIP3 requirements, which were then converted into Heidelberg-compatible ink preset files using Heidelberg’s interface software. These files were transferred to the last press station via smart cards for ink preset adjustments.
As digital technology advanced, networked data transmission became more popular. To support this, we set up a dedicated server to store CIP3 data, allowing each machine’s control terminal to access different directories and retrieve the appropriate ink preset files. This significantly accelerated the adoption of ink preset technology across the company.
Later, we upgraded our Heidelberg eight-color and five-color sheetfed presses, which came with the latest version of Prinect Prepress Interface (PPI) software. This new software offered more detailed customizable parameters and a more standardized workflow.
Through the implementation of CIP3 ink preset technology, we noticed a significant reduction in the ink adjustment range after startup and a shorter boot-up time. As one of our experienced print masters put it, “In the past, adjusting ink required a lot of experience. Now, the correct ink range can be achieved right from the start.†This allowed skilled operators to focus more on maintaining print quality rather than spending time on initial adjustments.
(1) Newspaper Printing Machines
After successfully applying CIP3 ink preset technology on the Heidelberg press, we decided to implement it on our newspaper rotary presses. Due to the time-sensitive nature of newspaper printing, minimizing startup time was crucial, and ink volume adjustment was a key factor. Using ink presets significantly reduced the time spent on this step, making it an important efficiency gain.
After researching, we found that our newspaper rotary press could directly receive CIP3 standard files for ink presets or convert 1BitTiff files for the same purpose. After comparing both methods, we chose the 1BitTiff approach because it not only provided accurate ink preset information but also included screen soft proof details, making it more versatile. We tested using a 3D resolution file at 300dpi with a screen line of 65lpi, and it met all our ink preset requirements.
As a result, the startup time for the newspaper rotary press dropped from 10–20 minutes to just 3–4 minutes, and the number of wasted sheets during startup decreased from 11–12 packs (200 copies per pack) to 4–5 packs. The cost savings were clearly noticeable.
(2) Commercial Rotary Presses
Our Komori commercial rotary press plays a vital role in printing teaching materials and DM orders. The PCC software used with this press can convert PPF files into PQ4 format, which is compatible with the Komori press. It also allows for secondary optimization of ink settings, enabling personalized customization of the standard CIP3 data for better performance. Additionally, the folding unit of the Komori press can access layout information from the CIP3 data, automatically setting folding parameters and ensuring precise digital positioning with high-speed folding equipment.
In the past, experienced print masters had to manually adjust the layout before printing. Now, they have a more accurate basis for pre-inking, eliminating the need to judge based on feel. With the ink area covering the entire image area, they only need to make minor adjustments based on the preset data.
The success of ink preset technology relies heavily on the press itself, not just the pre-press. Since the ink preset data is calculated based on the ratio of halftone to blank areas, the results are fixed. However, the actual ink amount applied depends on the condition of the press. Issues like worn ink fountains, dirty ink blankets, or improper roller pressure can affect the accuracy of the ink discharge.
Attention to detail is essential. During implementation, we found that several small steps significantly improved performance. For example, replacing the blanket one week before testing, cleaning and adjusting water and ink rollers, checking fountain solution temperature and conductivity, replacing the ink fountain film, and standardizing pre-press output conditions. These steps helped maintain consistent printing conditions, ensuring that the ink amounts matched the preset data as closely as possible.
Offset printing is an art that balances water and ink. Experienced operators often rely on years of practice to get it right. Today, technological advancements are helping print operators improve faster. Alongside ink preset technology, systems like Heidelberg’s CPC and the Dutch QI system allow for automated ink control in certain steps. Our company fully recognizes the value these technologies bring—enhanced product quality, increased production efficiency, and reduced workload for operators. This gives them more time to monitor and stabilize the printing process, while using feedback data to manage production effectively. We believe that digital printing technologies like ink presets will continue to grow in popularity, bringing greater convenience and efficiency to the industry.