2019

THE PRINTER’S GUIDE TO G7 IMPLEMENTATION

ADDENDUM FOR FLEXO
WRIT TEN BY: RON ELLIS

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T H E P R I N T E R ’ S G U I D E T O G 7 I M P L E M E N TAT I O N

ADDENDUM FOR FLEXO

Performing G7 on a flexo press is a similar process to performing G7 on an offset press, but there are some
important differences. In the G7 Master program, Idealliance recognizes the differences in flexo and allows
some exceptions to the normal G7 Master requirements. These flexo differences can be seen in the Idealliance
document ‘G7 Master Pass/Fail Requirements’ and are summarized below.

DIFFERENT PASS/FAIL REQUIREMENTS FOR FLEXO

MIN DOT
Newer flexo platemaking systems can produce a complete tonal range without issues. Older systems, which
may still be in use in many facilities, may not be able to image all the way down to 0. This results in a hard drop
off where there is no dot present. Minimum dot refers to the ability of a plate system to image a dot – the actual
printed minimum dot may be different. Many printers work to compensate with a ‘bump curve’ that manages
the minimum dot. Because of the minimum dot issue, Idealliance allows printers to ignore gray balance and
NPDC errors under 20%. While normally your plates should be able to handle errors well under 20%, this extra
exception can be helpful when preparing flexo plates for G7 Master submission.

Image on left shows the original image. Image in middle shows the effect of a 5% minimum dot. Image on right shows the effect of a 10% minimum dot.

AVERAGING
Flexo submissions to Idealliance are allowed to use an average of 3 samples instead of requiring that a single
sample meets the G7 requirements. This means that when calibrating, you do not need to rely on a single
sample to pass, but instead you are allowed to read multiple samples and average them together to achieve a
passing set of print samples.

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CALIBRATING A FLEXO SYSTEM TO G7

While calibrating a flexo system to G7 is similar to a litho system, there are a number of things that are different.
These range from how ink is targeted, to important details of how the machine is maintained and operated.

PRINTING STANDARDS AND FLEXO

Even though flexo has it’s own ISO standard based on flexo industry specifications (ISO 12647-6), many flexo
presses are aimed at the ink values provided in ISO 12647-2. Thus, calibrating a flexo press to G7 is often
done using a combination of ISO standards for flexo and litho, including the use of CGATS21/PAS 15339
characterization data.

STANDARD TITLE USE

Graphic technology – Process control
for the production of half-tone colour
ISO 12647-6:2012 Used for hue angles for inks
separations, proofs and production prints –
Part 6: Flexographic printing

Graphic technology – Process control

for the production of half-tone colour
ISO 12647-2:2013 Used for ink colors/chroma targets
separations, proof and production prints –
Part 2: Offset lithographic processes

Graphic technology – Printing from

Methodology for paper adaptation
CGATS 21-1 digital data across multiple technologies –
and calibration
Part 1: Principles

Graphic technology – Printing from digital

CGATS 21-1 data across multiple technologies – Part 2: Used for characterization data
Reference characterization data-2013

Graphic technology – Printing from Modified duplicate of CGATS 21.

ISO PAS 15339-1 digital data across multiple technologies – Methodology for paper adaptation
Part 1: Principles and calibration

Graphic technology – Printing from

digital data across multiple technologies Modified duplicate of CGATS 21.
ISO PAS 15339-2
– Part 2: Characterized reference printing Used for characterization data
conditions, CRPC1-CRPC7

Print standards used for flexographic printing

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INK
Similar to G7 for litho, flexo inks are targeted to match characterization data or an industry print standard.
An example of characterization data would be GRACoL 2013(CGATS-21 CRPC-6) or any of the Idealliance
Characterized Reference Print Conditions (CRPC). Because the ISO standard for inks referenced in ISO 12647-6
has been withdrawn, most flexo providers match the ink values of a published CRPC such as GRACoL 2013.
One important difference in how inks are targeted in the flexo industry is that in addition to lab values, flexo inks
are also targeted using hue angles (h°) The recommendation for the hue angle is to be within +/-2°.

METRIC HUE ANGLE (DEGREES)

COLOR
COLOR L a b C h° NON-LIGHT-FAST INKS LIGHT-FAST INKS
Yellow 89 -5 93 93 93° Cyan 233° 233°
Magenta 48 74 -3 74 357° Magenta 357° 12°
Cyan 55 -37 -50 -62 233° Yellow 93° 100°
Black 16 0 0 0 N/A Red 36° 40°
Ink Values for ISO 12647-2:2013 Green 160° 62°
Blue 290° 296°
Hue Angles Values for ISO 12647-6:2013

PROCESS CONTROL CONSIDERATIONS

A flexo calibration using G7 is similar to a G7 calibration for other print processes. Prior to beginning the
calibration, it is important to make sure that all the variables are documented so that they can be repeatable in
the future. Idealliance has a flexo prequalification kit that includes a form which will help you to document your
press conditions. Some of the variables for each flexo print condition include:

} Dot Shape } Viscosity

} Plate Type and Relief } Blade, Blade Edge, Blade Material
} Resolution } Color
} Post Processing or Baking } Dryer Temperarture
} Metering System } Anilox Roll, Condition, and Count
} pH } Anilox Volume
} Mounting Tape

If the calibrated press runs are not performed with the exact same conditions each time, then it may be difficult
to achieve gray balance and acceptable results. Flexo platemaking and setup can take much more time than a
similar lithographic setup, and additional time should be allowed.

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PREPARATION OF THE PRESS FORM

G7 press calibration test forms can be downloaded from www.idealliance.org. However, often times, these test
forms are too large for use on narrow web flexo presses. In this case, you also have the option to make your own
test form according to the size of your press. If you decide to create your own test form, be sure to include at
least two P2P51 targets on the form. If press form space is an issue, keep in mind that there are mini and micro
P2P forms that can also be used. In addition, Idealliance will also accept the much smaller G7 Verifier target for
G7 submissions. Finally, before running the test form, it is important to measure the plate to be sure it is correct.
Note that different line screens and screening types will require different plate curves.

1ST CALIBRATION RUN

The first calibration run has 2 main objectives:
} Ensure that ink solids can be adjusted to the correct color and hue angle for solids and overprints
} Obtain a linear sheet for measurement and creation of initial curves

Note - In G7 we do not have static target density numbers. Instead, we record the final density values for that ink
and press combination that produced our target LAB measurements.
Each ink solid is measured, compared to the reference solid, and then adjusted accordingly. For example,
if yellow should be L*89 a*-5 b*93, but the measurement is L*90 a*-4 b*89, the press operator will need to
increase yellow density. The goal here is to achieve the lowest delta E and hue angle on press when compared
to the reference print condition. For GRACoL 2006 the required ∆E2000 is 3.5 or less for C, M, Y solids, 5 or less
for K, and 4.2 or less for overprints. Ink targeting requires increasing or lowering the strength of the ink until
we achieve the lowest possible delta E. This may require changing an anilox roller, changing the ink build, or
modifying other press controlled variables. If the press operator cannot move the ink to the correct values, then
you may need to go back to the ink lab. In some cases you may not be able to achieve the desired values, and
in this case, consider calibrating to the G7 Gray compliance level rather than G7 Targeted level. Most current
measurement devices have the ability to provide you with the ΔE2000 calculation and LAB numbers.
Just like with a litho calibration it is important to know that you can submit G7 relative measurements. The
Techkon SpectroDens can provide you with both absolute and substrate relative E2000 E and LAB numbers, as
well as a density recommendations and prediction of the lowest delta E (which makes the ink targeting process
very easy). Remember the color of the paper has a great effect on your ability to achieve these solids and
overprints. A paper that is either too blue or too yellow will make some of these difficult to achieve.
Once you have the solids and overprints dialed in, you are going to read the solids and these will become
the target densities your operator will use. Once you have achieved correct color, take at least 3 sheets for
measurement. Look closely before leaving the press as bad sheets are often the culprits in failed
press calibrations.

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MEASUREMENT AND CURVE CREATION

The next step is to measure the sheets. The sheets should be measured using the same M condition
measurement parameters as the reference print condition. For GRACoL 2006 this is M0, D50, 2 degrees and
white backing. For GRACoL 2013 or any of the CGATS 21 G7-based print conditions this is M1, D50, 2 degrees,
and white backing. Changing the measurement parameters has a big effect on the measurements, so make
sure your settings match. This can be done using a measurement application provided by the instrument
manufacturer, or in Curve 4 can be done directly within the application.
We are going to measure 3 press sheets, with 2 targets on each sheet. (For flexo it is especially important to
make sure we measure multiple samples.) Name the measurements noting sheet number and position so you
can make corrections if there are issues with the targets.
Once measured, we launch the software for making curves. This process is exactly the same process as described
in the litho section.
When making curves for common flexo prepress systems you should be able to export curves in the TED or
CGATS formats for import into your RIP systems. When generating your Curves, pay close attention to the
minimum dot. You may need to add a bump curve here to make sure the minimum dot shows.

2ND CALIBRATION RUN

When we go back on press, we are going to run back up to the same exact densities and color. This works
best if the operators have left the press alone and have not run any other jobs. Make sure the same press
conditions are in effect, including the same anilox rollers. Once the sheet is back up to color, we will check ink
solids and overprints to make sure they still meet the requirements of our reference print condition. If these
vary from the reference print condition or the prior run, then point out to the press operator what needs to be
adjusted. Once the press sheet is at correct color, we can begin to evaluate gray balance. For this, we are going to
do a quick check of the HR patch as described in the litho section. If adjustments need to be made, we can ask
the press operator to make slight adjustments. If we cannot achieve gray balance we may need to make further
plate adjustments.

EVALUATING YOUR RESULTS

Once we have measured the sheets, we will import the measurements back into Curve 4. On the first screen we
should see a much closer match between the target NPDC curves and our printed result. Next, we will check
the Analyze tab and select Summary to make sure we have achieved the desired tolerance level. This summary
screen is new to Curve 4 and is matched to the G7 Master Pass/Fail requirements. Finally, we will click on the
G7® tab. Here we can see that both our NPDC and gray balance are within tolerance. (If not, we must regenerate
correction curves and go back on press.) At this point we have achieved our G7® calibration.

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In the two images above, notice the NPDC graphs are now close to the target NPDC Curve, and gray balance in
the bottom right of the screen is close to the target aim.

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Curve 4 features a G7 Master report that shows compliance to G7 Master levels. In this screen, you can see our
measurements have passed the G7 Targeted compliance level.

RECORDING PRINT METRICS

Once you have a final G7® press sheet, save several sheets for reference and record the print metrics. These
measurements will be used for troubleshooting in the future if there is a problem with proof to press match.
Here are the metrics we want to record using the press operators instrument: (Keep in mind we already have an
additional set of metrics recorded in the Curve 4 software)

LAB VALUES FOR SOLIDS DENSITY FOR SOLIDS

Used to tell if ink is the correct color, has changed, Used for press control
or has become contaminated  OT GAIN FOR ALL COLORS, 25%, 50%, 75%
D
LAB VALUES FOR OVERPRINTS Used to tell if there is an issue with a specific unit
Used to tell if overprints have changed, chemistry on press
issues, ink issues
In addition to the above you will need to have a record
LAB VALUES FOR HR, HC, SC of all the print variables such as temperatures, anilox
Used to check gray balance rollers, curves, etc. so that production can use the same
CMY DENSITY FOR HR settings to run future jobs.
Used as an easy way for press operators to check gray
balance during production.

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LEARNING MORE
You can learn more about G7® at the following sites:
http://www.teckonusa.com
The Techkon site has articles, whitepapers, downloadable forms, and webinars about G7®.
http://www.freeprocesscontrol.com
The freeprocesscontrol site has additional articles and information about G7®.
http://www.idealliance.org
The IDEAlliance web site has information about G7®.
http://www.gracol.org
The GRACoL page on the IDEAlliance web site has the most current updated information about GRACoL and
G7®, as well as information on IDEAlliance activities.

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