KEY CONSIDERATIONS FOR PREPRESS WORKFLOW

In the development of prepress workflow in this sector, brand owners demand accurate, consistent and high-quality colours, printed on different materials with a fast turnaround. Printing large quantities of personalised products – at speed – on inkjet presses is also becoming the norm. To stay efficient and reduce waste, having a smart, integrated prepress workflow is essential.

Smart prepress workflows leverage automation and integrate with other systems such as the Digital Front End (DFE), Management Information Systems (MIS) and Enterprise Resource Planning (ERP). This streamlines processes and reduces manual interventions, leading to faster turnaround times.

Today’s labels and packaging often feature intricate designs with high colour-fidelity requirements. Managing and optimising these designs for digital-inkjet printing can be complex and time consuming. 

Automation should handle repetitive tasks – such as step-and-repeat, layout imposition and file preparation – to maximise media usage and press efficiency. This is especially important when printing labels and packaging where variable data is to be printed. In these cases, every label may be different and may include a barcode, manufacturing data and serial number. Smart prepress workflows incorporate specialised software for managing variable data, ensuring that personalised elements are correctly handled and efficiently processed.

Important tasks, at this stage of the workflow, include automatically examining the file to detect and fix elements that will affect the result. These include small text or technical inks that knock out artwork, artwork beyond the printing area and barcodes in more than one colour. Other tasks include excluding information panels not intended for printing and eliminating technical or other non-printing colours. Additionally, rotating and scaling images to align with the finishing requirements, as well as adding extra white layers when printing onto transparent materials to ensure optimal print visibility and quality.

The ability to scale and customise workflows and use data from and to an existing MIS, greatly enhances efficiency. This integration minimises the time and errors associated with double data entry and streamlines productivity by ensuring seamless data flow and consistency across all systems. Moreover, it is possible to create personalised workflows that effectively function as an MIS. This further optimises operations and resource management.

To stay efficient and reduce waste, having a smart, integrated prepress workflow is essential

How data is processed and stored should also be a key consideration. Cloud Computing and Edge computing both process and store data, but in different ways. 

In Cloud Computing, data is sent to centralised servers (the Cloud) for processing and storage. This can involve long distances, leading to delays and higher bandwidth use. It is great for tasks that don’t need immediate response and can benefit from the vast resources of centralised data centres. It is also successful for the collaboration required in workflows. 

Smart prepress workflows incorporate specialised software for managing variable data

Cloud-based collaboration tools enable multiple stakeholders to review and approve designs in real time, speeding up the approval process and reducing the likelihood of errors. The ability to interact securely within a prepress workflow, over the internet, offers significant advantages. With zero deployment required for end users, partner companies can seamlessly adopt multi-location operations. This capability enhances flexibility, allowing for scalable solutions to meet varying production demands. By leveraging secure internet interactions, organisations can ensure efficient and co-ordinated workflows, regardless of geographical location, thereby optimising overall production processes. 

Edge Computing processes data close to where it is created, such as on local devices or nearby servers. This reduces delays and bandwidth use, making it ideal for real-time applications. Processing high data rates locally also allows for quicker handling of large volumes of information – crucial for real-time applications such as driving inkjet presses.

Using a mix of Cloud and Edge Computing, also known as Hybrid Computing, creates a flexible and efficient system. In this approach, data and processing tasks are strategically distributed between centralised Cloud servers and local Edge devices. Critical data that needs immediate processing and quick response times is handled locally on Edge devices, reducing latency and bandwidth usage. Meanwhile, less time-sensitive data or tasks requiring significant computational power and collaboration are sent to the Cloud, leveraging its vast resources and scalability.

Using a sophisticated colour-management system (CMS) ensures accurate and consistent colour reproduction across different substrates and printing conditions. Here, it is important to connect the prepress workflow to the DFE to share information. By knowing what DFE media setups are available – and assigning these to specific jobs – operators ensure the job can only be printed using the correct DFE setting. 

Inkjet OEMs in the label and packaging market, need a solution designed to streamline and automate prepress workflows

It is important to emphasise that an OEM should work with a partner to create a custom workflow solution. Bringing an inkjet press to market requires a specialised skill set and significant engineering effort, which can necessitate workflow specialists. Some customers may have specific challenges that need tailored solutions. Solutions are available that offer printers advanced tools and automated processes to ensure that the supplied PDF is press ready. High-quality printed jobs begin with well-prepared artwork and these solutions optimise performance, minimise waste and incorporate printed controls for downstream production considerations. Partnering with a company that has proven expertise in the label and packaging print industry – and owns all the key components from PDF preparation to printhead electronics – can be a significant asset for any printing solution.

In addition to current needs, OEMs should consider future scalability and compatibility. By providing a prepress workflow solution, customers will have the flexibility to upgrade and expand their operations as requirements evolve. The solution needs to be easily integrated with open, industry-standard communications protocols. This future-proofing approach ensures that the OEM’s offering remains relevant and capable of meeting the growing needs of its customers.

To future-proof prepress workflows, OEMs should consider the following strategies:

Adopt scalable solutions – Implementing scalable workflow solutions allows for flexibility and growth. As business demands increase, the workflow system should be able to handle larger volumes and more complex tasks, without compromising efficiency.

Implement robust data management – Effective data management ensures that all digital assets are well-organised, easily accessible and secure. This includes implementing data back-up solutions and maintaining a clean and structured file system.

Embrace connected Cloud and Edge technologies – Connect Cloud-based solutions that offer enhanced collaboration, storage and processing power. Use Edge technologies, built into the inkjet press, to deliver real-time feedback and high data throughput. 

Inkjet OEMs in the label and packaging market, need a solution designed to streamline and automate prepress workflows, thus boosting the press’s productivity. By considering these key factors and future-proofing strategies, OEMs can create efficient, reliable and scalable workflows that meet current and future demands in the industry. It is also crucial to offer a flexible and extendable workflow solution. This solution should have the capability to adapt to different customer workflows, accommodating their unique requirements and preferences. Furthermore, seamless integration with the DFE at the Edge is paramount, enabling a smooth and efficient transition from the design phase to printing. By integrating the workflow solution with the DFE, automated lights-out printing operations can be achieved. As a result, manual intervention is minimised and productivity maximised.