File Requirements

1. Broad guidelines for preparing printing layouts.

  • All fonts should be converted to curves.

  • If the overprint is necessary for the ink, please set it manually at the stage of preparing the layout.

  • If you need any indent fields please add them to your file manualy.

  • The file should not contain inapplicable elements:

    • arrows, bleeds;

    • loops in the contours;

    • inapplicable objects, separate dots, text, etc.

  • Bitmap images must have a resolution of at least twice as plate screening.

  • The layouts should contain elements of the CMYK color model or be colored in Pantone spot printing colors and should not contain RGB objects.

  • We recommend to use standard inks and color names from Pantone libraries

  • Layouts should not contain OLE objects.

  • If any elements from clipart files are used in the layout, they should be adapted for flexo printing and simplified as much as possible (inapplicable elements must be removed).

Minimum dimensions of the layout elements *

Parameter
Plate thickness 3,94 mm and more
Plate thickness before 3,94 mm
text /текст
5 pt
3 pt
separate line /отдельная линия
0,3 mm
0,1 mm
separate dot /отдельно стоящая точка
0,75 mm
0,2 mm

*it is necessary to conduct testing in order to clarify the ability to display minimal objects.

Gradients should contain the same number of inks both in the initial color and in the final color.

The dimensions of the layout should be subject to shortening in the direction of printing (if nessesary).

2. For the layouts created in CorelDraw.

  • files should not contain special effects, such as:

    • Interactive Fill,

    • fill objects with a pattern (two-color, multi-color, dot) from a scroll,

    • Special Fill,

    • Pattern Fill,

    • as well as the Lens effect.

  • If the Interactive Drop Shadow effect was used, then it is advisable to use the Separate operation.

  • Images to which these effects are applied must be converted to Bitmap mode.

  • The maximum number of curves nodes must not exceed 6000, otherwise this object or its part will be ignored.

  • When creating a layout in CorelDraw 12 and any its version below 12, you must set the miter limit parameter - 5,0 in order to control the stroke shape.

  • The following features should be noted for CorelDraw:

    • If the initial gradient color contains a certain Pantone, then in the final color should be the same Pantone (percentage of this Pantone). The gradient from Pantone to CMYK (even to “0” CMYK) gives the CMYK result (Pantone will not be in the gradient) at color separation.

3. For the layouts created in Adobe Illustrator.

  • you need to set High resolution in the file parameters;

  • you need to set 300ppi High resolution in the parameters of the bitmap effects;

  • only visible layers are sent to the output, the operator does not disconnect and does not switch layers, if it is necessary to output a separate layer, it must be taken out in a separate file;

  • a TIFF file must not contain any layers, contours, or alpha channels;

  • in Adobe Illustrator, when using links in DCS 2.0 format, the encoding must be ASCII;

  • there should be no gubbish in the screen images (watercolor washes, brushing marks, halos, shadows, separate pieces);

  •  white objects should not be assigned with an overprint (overprint white is prohibited).

4. Requirements for PDF files.

  • PDF 1.3 - 1.7;

  • color model is the same as the source file;

  • bitmap objects without downsampling the resolution and without JPEG compression (Zip compression is allowed)

 

5. Special notes about the Computer-to-plate output.

A round shape of a half-tone dot is used in the plates production. Standard screen rotation angles for flexographic printing: Сyan - 7°, Magenta - 67°, Yellow - 82°, blacK - 37° The 37° angle is used for Pantone inks by default.  When placing an order for each ink you can choose the angle from the list of standard ones.

 

 Possible screen ruling for Computer-to-plate output with flexo angles:

  • with 2540 dpi engraving resolution: 55, 63, 71, 79, 86, 95, 102, 110, 126, 142, 150, 157, 165, 189, 204 lines per inch.

  • with 4000 dpi engraving resolution: 99, 112, 124, 136, 149, 161, 174, 198, 223, 236, 248 lines per inch.

 

Possible screen ruling for Computer-to-plate output with offset angles:

  • with 2540 dpi engraving resolution: 52, 60, 67, 76, 82, 90, 97, 112, 119, 126, 134, 138, 149, 156, 163, 171, 179, 189, 199, 211 lines per inch;

  • with 4000 dpi engraving resolution: 105, 119, 129, 141, 152, 176, 188, 199, 211, 217, 235, 245 lines per inch.

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By default, the standard Computer-to-Plate technology is used for engraving with a resolution of 2540 dpi: exposure by lamps and a classic amplitude-modulated halftone screen with a round dot. NExT flat-dot technology is used for 4000 lpi engraving resolution: exposure with super-powerful LEDs, a combined rasterization algorithm - an amplitude-modulated screen over almost the entire tonal range and a frequency-modulated screen in bright halftones. Additional testing will be required to select the most preferable micro-rasterization method and screen type for your printing press.

Special test elements, as a rule, are present on the printing plate operating set and are displayed when printing on each repeating image unit.