Closed-loop Color Control for Offset: A Deep Dive

Closed-Loop Color Control for Offset Printing

Closed-loop color management control removes the need for human intervention on press. A print job no longer requires a well-trained human eye to adjust ink on press, as closed-loop systems make automated press adjustments and maximize efficiency, which over time reduces the amount of waste produced on press. In digital printing, color management is the process of ensuring that color reproduction is exact and consistent with the desired standard. This control is important to reduce wasted materials and substrate over time. With print work, color spaces such as CMYK are often used, whereas RGB is the color space typically used for digital work. LAB is a global color space typically used in printing. These color spaces are important when determining how colors will be reproduced on press.

Understanding Closed-Loop Color Control in Sheetfed Offset Printing

Techkon’s SpectroDrive is a press-side, automated, scanning solution for offset presses. This spectrodensitometer runs on a precision track that can be ordered in lengths up to 81 inches. The track can be mounted directly onto the press console so sheets can be pulled from the press, placed on the console, and measured automatically. After measurement, solid ink density, TVI, Delta E, and more are displayed to the press operator.

Key Components of Techkon’s Closed-Loop System

Techkon’s closed-loop system, PressLink, is a cost-effective solution that enables manufacturers to update a wide range of press makes and models. PressLink automates the color control process, as the software is able to automatically control the press ink keys. This software, when paired with the SpectroDrive (Techkon’s automatic scanning spectrodenistometer), makes for even more precise color measurement.

SpectroDrive: Automated Scanning for Precise Color Measurement

Automated scanning spectrophotometers are color management devices that are often stationary and are perfect for production and manufacturing style settings. Techkon’s SpectroDrive is a type of automated scanning spectrophotometer that runs on a precision track. The device can also be removed from the track and used as a handheld instrument for “spot check” measurements. The SpectroDrive is reliable and efficient and can scan a 40″ press sheet in just 8 seconds.

PressLink Software: Real-Time Ink Key Adjustments

PressLink is Techkon’s closed-loop color management device that combines the Spectrophotometer and SpectroDrive with color control software. This software is installed with the press-side ink key console and makes real-time ink key adjustments. The software moves the keys for the press operators, in turn simplifying the color theory process, removing the need for guesswork, and reducing make ready times as well as waste.

Integration with Existing Press Consoles

Integrating color-managed workflows into existing presses is not far out of reach. For printers who are looking to maximize their profit gains and meet customers’ ever-changing quality specifications, this integration is key. These closed-loop press side color management systems improve the stability of your print processes, even on older presses. Techkon’s systems are compatible with manufacturers such as Ryobi, Heidelberg, and Komori. This helps to meet customers’ demands for greater color accuracy and color consistency.

Benefits of Implementing Closed-Loop Color Control

Closed-loop color control is a game changer in the world of printing. In high-volume print settings, every minute or piece of material wasted adds up. Closed-loop color control systems allow press operators to determine the efficiency and accuracy of a job, while the press is still running. A closed–loop system works by using real-time measurements to automatically adjust the ink densities during the print run. This ensures that the color reproduction will align with the desired color standard, which helps press operators feel confident that the range of colors they see on the screen during pre-press match the final printed product, as a screen may follow different color spaces than the press. This color management process is important to control and standardize the color output across multiple print jobs, which can help simplify the color theory process. For more information about Techkon’s closed-loop solutions, feel free to visit our website.

Improved Color Consistency Across Print Runs

A common issue during the printing process includes color consistency across all print runs. This issue can be resolved by using an effective color management system that uses automation to ensure consistency across each job. Furthermore, closed-loop color control goes a long way in improving color consistency across all print runs. For printers who may be completing jobs across multiple locations, closed-loop systems ensure that waste is minimized, and that each job meets the customers’ desired specifications.

Reduced Make-Ready Times and Material Waste

Closed-loop color control systems do a great deal in reducing make-ready times and material waste. Each second a press is running not within a specified tolerance, material, ink, and time is wasted. This can happen quite frequently, as color theory can be hard to master. Effective color management systems, such as a closed-loop system, means that press operators no longer need to stop a job while on press to measure precision and accuracy. The system completes this task as the press is running, which reduces make-ready times and waste.

Enhanced Operational Efficiency and Cost Savings

In the press room, keeping track of costs is important. As mentioned above, every minute that a job is running not in tolerance is wasted money. Furthermore, the printer loses money if a job does not meet the expectations and specifications of a brand. By implementing a closed-loop color management system, press operators increase efficiency, as they no longer need to stop the press to make adjustments or measurements.

Integration and Compatibility

Integration with Techkon’s range of different devices is simple. All we require is information about the make/model of the press and information about the press console. This allows printers efficient and easy access to color-managed workflows. Furthermore, in integrating a new system with an existing press, it is important to consider the color profile of the press. These color profiles determine exactly how the press behaves, based on a number of variables such as material and type of substrate. Color profiles are important, as each press is unique, which can impact the way it operates.

Retrofitting Older Press Models

Implementing closed-loop color control for offset is a great way to update and enhance older press models. This is a rather seamless process, as Techkon’s different devices are compatible with all press makes and models, such as presses manufactured by Mitsubishi and Manroland.

Seamless Integration with Prepress Workflows

Techkon’s closed-loop systems will fit seamlessly into your prepress workflows. Techkon’s devices are designed to be compatible with any press manufacturer, making them a perfect solution for all makes and models.

Compatibility with Various Press Manufacturers

As mentioned above, Techkon’s different devices are compatible with various press manufacturers. This takes a lot of the trouble out of the integration of a closed-loop device into a newer or even an older press.

Future Trends in Closed-Loop Color control for offset

As technology continues to advance, closed-loop systems have become a staple for many printing companies. With older presses, it will eventually come time to do a cost analysis and compare the price of a completely new press or invest in a closed-loop system to enhance the accuracy of the press. For jobs that require color critical work, closed-loop systems remove the need to rely on a well-trained eye. Nowadays, many printing companies are following this trend and turning to closed-loop systems to keep their older presses running like new for longer.

Advancements in Automation and Machine Learning

With advancements such as Artificial Intelligence, systems are able to automatically pick up on trends and adjust to specific profiles on press. Overall, artificial intelligence and machine learning make these systems quicker and more precise, which helps to enhance the efficiency of your workflow.

Sustainability and Environmental Impact Reduction

With the accuracy and control that closed-loop color management systems offer, there is often a reduction of wasted materials. The more time that is spent out of tolerance, the more waste is produced. Closed-loop systems are fully automated and reduce a lot of the time and waste that comes with certain print jobs.

Ink Presetting and Job Setup Optimization

Prior to the press run, closed-loop systems, such as the SpectroJet, analyze a digitally imposed image and automatically open and close ink keys on press. This step aligns the ink densities with the prepress file, which reduces the time required and the number of adjustments needed throughout makeready.

Utilizing CIP3/CIP4 Data for Accurate Ink Key Presets

CIP3/CIP4 data is a type of job metadata. In terms of ink key presets, this data is beneficial to gain information about the job itself. CIP3/CIP4 data shares information about the dimensions of the job, the range of colors of the job, as well as how many impressions will be needed to print an image.

Streamlining Job Setup with Automated Ink Distribution

With closed-loop systems, such as PressLink, ink key adjustments can be handled without the need for human intervention. PressLink’s ability to move and adjust the ink keys for the press operator streamlines job setup as well as increase efficiency and reduces waste.

Operator Training and User Experience

With Techkon’s closed-loop solutions, there is no longer a need to worry about the time that will be lost while training operators on how to use the system. Techkon’s devices are user-friendly and are designed with intuitive interfaces for limited training needs and efficient usage. Furthermore, Techkon offers on-site training to assist users in learning about the system.

Intuitive Interfaces for Efficient Operation

In general, closed-loop color control systems take out the need for human intervention. The machine will not always be perfect, and in some cases, the operator may need to jump in and make adjustments as needed based on their expertise and knowledge. The intuitive interfaces and simple design of Techkon’s closed-loop systems makes it easy for press operators to learn and understand the system, which in turn makes for an even more efficient operation.

Reducing Learning Curves with User-Friendly Design

Techkon’s closed-loop systems, such as PressLink, are user-friendly and easy to learn. This reduces the time spent training and becoming comfortable with the system, meaning that more time can be spent in-color on press. The learning curve is essentially minimal with these types of closed-loop systems, as the software does a lot of the work for you.

Maintenance and Calibration of Closed-Loop Systems

Like any other device, calibration and regular maintenance is important for closed-loop systems. Regular maintenance and calibration provide press operators’ peace of mind that their color-managed workflow is performing with accuracy and reliability.

Ensuring Long-Term Accuracy with Regular Calibration

With any device, regular maintenance and calibration is crucial to ensure accuracy across all print jobs. There are two types of calibration that Techkon’s devices must undergo. The first is a smaller calibration, in which the handheld device can be calibrated easily by placing the device on the charger, which has a small white tile built in that the device is calibrated with. The second type of calibration is larger and requires the device to be sent to Techkon USA in Danvers, MA. This calibration is free with the Planned Maintenance Program. Users will be sent a loaner device during this routine calibration.

Simplifying Maintenance Procedures for Minimal Downtime

At Techkon, we understand how important it is to decrease downtime during maintenance procedures. Techkon’s Planned Maintenance Program (PMP) ensures that you will be left with a loaner device during the routine calibration, as mentioned above. This loaner device is crucial to keep your workflow efficient during any maintenance procedures.

Return on Investment and Cost Analysis

With any investment in a new device, it is smart to investigate the cost of the product, as well as the benefit and cost savings it will bring you. Techkon’s PressLink is able to significantly reduce costs and increase savings because of precise ink key presetting, fast and accurate press sheet color bar scanning, and a sophisticated, closed-loop hardware/software connection.

Calculating ROI with Techkon’s PressLink System

To determine Return on Investment (ROI) of Techkon’s PressLink, check out our ROI calculator.

Long-Term Savings through Waste Reduction and Efficiency

With automated or closed-loop color control for offset systems, users can expect shorter make-ready times, reduced waste, and enhanced efficiency. All together, these lead to significant cost savings and an increase in profits over time.

Enhancing Closed-loop color control for offset through automation

Overall, closed-loop automation enhances sheetfed offset printing by increasing efficiency and reducing waste. By removing the need for guesswork and human intervention, jobs can be completed at a faster pace, while maintaining the necessary accuracy and precision. For more information about how you can integrate closed-loop color control into your offset, flexo, or digital printing process, visit our website.