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VPMP POLYTECHNIC,
SEC-15, G’NAGAR.

REPORT ON:
“METAL & METAL OPERATIONS”

PREPARED BY: GUIDED BY:

BHAGAT DARPAN J. MR M.N.PATEL
(086540319006) (L.M.E)
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CERTIFICATE

This is to certifiy that Mr. Kayastha Brijesh R. of ME-1 Class, Roll

No:-086540319029 has satisfactory completed his term work in
project for the term ending in 5th sem. 2010-2011.

Date:

Signature of faculty Head of

Department
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ACKNOWLEDGEMENT

We are very much encouraged in presenting our term work

project entitled “PRINTING PROCESS, METHOD TO PROCESS &
MACHINE USED FOR IT”. It has been our humble Endeavour to fulfill
whatever is expected from the students of diploma classes.
We gratefully acknowledge the help and directional guidance given
to us by our respected guide shri MANOJ.N.PATEL. We take this
opportunity to extend our sincere thanks& gratitude to him. But for him, it
could have not been possible for us to bring out this work in the final
form.
We also wish to put on record our appreciation of the sincerity and
painstaking nature of shri KARTIK G. KAYASTHA without whose
invaluable efforts our project would not been complete.
We are failing in our duty if we do not thank all those who have
helped us directly or indirectly in carrying out our project work
successfully.
Though every care has been taken to check mistakes and
misprints, yet it is difficult to claim perfection. We have made every effort
to make the project as complete as possible .But as far as the subject at
large is concerned, it is a never-ending Endeavour.
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INDEX
SR.NO. TITLE PAGE
NO.

1 INTRODUCTION 6

2 TYPES OF PRINTING 6
PROCEESES

3 DEFINITION OF PRITINTING 7
PROCESSES

4 PAPER CUTTING MACHINE 8

5 DEVELOPMENT OF PRINTING 10
PRESS
6 WORKING OE PRINTING 11
PRESS
7 IMPACT OF PRINTING 12
8 CRATING MASTER DIE 16

9 OFFSET LITHEROGRAPHY 18

10 METHOD OF PRINTING PREES 20

11 HISTORY OF OFFSET PRINTING 21

12 TYPES OF COMMERICIAL 25
OFFSET PROCESSES
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13 PLATE MAKING 29
14 REFERENCE 35
15 CONCLUSION 36

 Introduction:
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This flagship business of Hi Scan group has propagated us amongst the

national players.In many ways ,Their printing excellence has awarded as a status of
leadership.Some of their Machines and system include.

 Heidelberg offset Printing Machines six colour/four colour.

 Online lacquering facilities.
 Computerized print control.
 Job recording system.
 Alcolour /Alcohol based damping.
 Production capacity of 1 lakh sheets per day.
 Packaging.
 Label printing.
 Web offset.

 Types of printing processes.

 Offset printing process.
 Gravure
printing
process.
 Diagram of
Offset Printing

 Definition of Offset
Printing: A plate
makes an inked
impression on a rubber-
blanketed cylinder,
which in turn transfers it
to the paper.

I thought it might be
useful and fun to blog a bit
about offset printing. The
 Page |7

printers Pixeltrip works with use offset lithography, and thermography

(raised lettering). So here goes...

First, what is offset lithography:

Offset Lithography is by far the most common form of commercial

printing.

The basic principle on which it works is that oil and water do not mix.
A litho printing plate has non-image areas which absorb water.

 Definition of gravure printing: It is a major process of

printing. In this process we can print anything on any sub-

PAPER CUTTING MACHINE

 Non Programmable Hydraulic Fully Automatic Paper Cutting Machine with

Sturdy Cast Iron Frame, Double Hydraulic Pressure, Low Pressure To check
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Cutting Line and high pressure to make a cut, Oil Dipped Bronze Reduction Gear
Box for noiseless and long running Life, Photo cell safety Device, Two handed
Cutting Cycle Switch for operators safety best suited for high speed production.

 Variant I) STAR High speed Fully automatic paper cutting machines with
specially designed electro magnetic Clutch & brake fitted with 2 hand push button
control With cut per cut safety, Infra red photo cell safety device with built in fail
Safe brake, individual Motorized back gauge. all accessories 2 Electric
Motor ,Measure Indicator , all accessories & Electricals and centralized hand
Lubrication pumpEtc(Selfclamp).(With Premium quality Steel knivesVariant II)
STAR High speed Fully automatic paper Guillotine With latest hydraulic power
pack, Air cushiontable,High Cutting speed, photo electrical safety device specially
designed electro magnetic Clutch & brake (Hydraulic clamp) (Without program)
(With Imported steel knives)

 Technical Specifications:

Hydraulic Fully Automatic Paper Cutting Machine Size 36" 45"

Max. Length 920 mm 1150 mm
Cuts per minute (continuous running) 40 40
Back Gauge Speed (Normal / Slow) 100 / 20 100 / 20
Back Gauge Travel Max 950 mm 1150 mm
Minimum Cut (residual) 26 26
Space Under Clamp 125 mm 125 mm
Clamp Pressure Min / Max (kgs) 450 / 4000 500 / 4000
Motor 5 HP 7 HP
Table Height 920 mm 920 mm
Gross Weight 2800 kgs 3500 kgs
Shipping Volume (m3) 3.5 4.0

 Standard Accessories with Hydraulic Fully Automatic Paper Cutting Machine:

 Electrical, 2 knives, 2 extension tables, cutting line indicator, photo cell device, 3
piece back gauge segments, knife changing kit and a set of tools
Optional Accessories: Computer (Programmable)
 Size Available 36” ,42” ,45”, 52”,65”, 72”
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HEIDELBERG PRINTING MACHINE

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 Development of the printing press

The original method of printing was block printing, pressing sheets of paper
into individually carved wooden blocks. It is believed that block printing originated in
China, and the earliest known printed text, the Diamond Sutra (a Buddhist scripture),
was printed in China in 868 A.D. The technique was also known in Europe, where it
was mostly used to print Bibles. Because of the difficulties inherent in carving
massive quantities of minute text for every block, and given the levels of peasant
illiteracy at the time, texts such as the "Pauper's Bibles" emphasized illustrations and
used words sparsely. As a new block had to be carved for each page, printing
different books was an incredibly time consuming activity.

Moveable clay and metal type are processes much more efficient than hand
copying. The use of movable type in printing was invented in 1041 AD by Bi Shag in
China. Shag used clay type, which broke easily, but eventually Goryeo (Korea)
sponsored the production of metal type (a type foundry was established by the
Korean government in the early (15th century). Since there are thousands of
Chinese characters (Koreans also used Chinese characters in literature), the benefit
of the technique is not as apparent as with alphabetic based languages. Movable
type did spur, however, additional scholarly pursuits in Song China and facilitated
more creative modes of printing. Nevertheless, movable type was never extensively
used in China until the European style printing press was introduced in relatively
recent times (thus bringing the technology full circle).

Although probably unaware of the Chinese/Korean printing methods (with

substantial evidence for both sides of argument), Gutenberg refined the technique
with the first widespread use of movable type, where the characters are separate
parts that are inserted to make the text. Gutenberg is also credited with the first use
of an oil-based ink, and using "rag" paper introduced into Europe from China by way
of Muslims, who had a paper mill in operation in Baghdad as early as 794. Before
inventing the printing press in 1440, Gutenberg had worked as a goldsmith. Without
a doubt, the skills and knowledge of metals that he learned as a craftsman were
crucial to the later invention of the press.
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 How a Printing Press Works

A printing press, in its classical form, is a standing mechanism, ranging

from 5 to 7 feet long, 3 feet wide and 7 feet tall. Type arranged into pages is placed
in a frame to make a forme, which itself is placed onto a flat stone or 'bed'. The type
is inked, and the paper is held between a frisket and tympana (two frames covered
with paper or parchment). These are folded down, so that the paper lies on the
surface of the inked type. The bed is rolled under the platen, using a windlass
mechanism, and the impression is made with a screw that transmits pressure
through the platen. Then the screw is reversed, the windlass turned again to move
the bed back to its original position, the tympan and frisket raised and opened, and
the printed sheet removed. Such presses were always worked by hand. After around
1800, iron presses were developed, some of which could be operated by steam
power.

 Impact of printing

 Effects of printing on culture

The discovery and establishment of the printing of books with moveable type
marks a paradigm shift in the way information was transferred in Europe. The impact
of printing is comparable to the development of language, the invention of the
alphabet, and the invention of the computer as far as its effects on the society.

Because of the printing press, authorship became more meaningful. It was

suddenly important who had said or written what, and what the precise formulation
and time of composition was. This allowed the exact citing of references, producing
the rule, "One Author, one work (title), one piece of information" (Giesecke, 1989;
325). Before, the author was less important, since a copy of Aristotle made in Paris
might not be identical to one made in Bologna. For many works prior to the printing
press, the name of the author was entirely lost.

Because the printing process ensured that the same information fell on the
same pages, page numbering, tables of contents, and indices became common. The
process of reading was also changed, gradually changing from oral readings to
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silent, private reading. This gradually raised the literacy level as well, revolutionizing
education.

It can also be argued that printing changed the way Europeans thought. With
the older illuminated manuscripts, the emphasis was on the images and the beauty
of the page. Early printed works emphasized principally the text and the line of
argument. In the sciences, the introduction of the printing press marked a move from
the medieval language of metaphors to the adoption of the scientific method.

In general, knowledge came closer to the hands of the people, since printed
books could be sold for a fraction of the cost of illuminated manuscripts. There were
also more copies of each book available, so that more people could discuss them.
Within 50-60 years, the entire library of "classical" knowledge had been printed on
the new presses (Eisenstein, 1969; 52). The spread of works also led to the creation
of copies by other parties than the original author, leading to the formulation of
copyright laws. Furthermore, as the books spread into the hands of the people, Latin
was gradually replaced by the national languages. This development was one of the
keys to the creation of modern nations.

Some theorists, such as McLuhan, Eisenstein, Kittler, and Giesecke, see an

"alphabetic monopoly" as having developed from printing, removing the role of the
image from society. Other authors stress that printed works themselves are a visual
medium.

 Background
The postage stamp is a relatively modern invention, first proposed in 1837
when Sir Rowland Hill, an English teacher and tax reformer, published a seminal
pamphlet entitled Post Office Reform: Its Importance and Practicability. Among other
reforms, Hill's treatise advocated that the English cease basing postal rates on the
distance a letter traveled and collecting fees upon delivery. Instead, he argued, they
should assess fees based on weight and require prepayment in the form of stamps.
Hill's ideas were accepted almost immediately, and the first English adhesive stamp,
which featured a portrait of Queen Victoria, was printed in 1840. This stamp, called
the "penny black," provided sufficient postage for letters weighing up to .5 ounce (14
grams), regardless of distance. To encourage widespread use of stamps, letters
mailed without them were now charged double at the point of delivery. After Britain,
Brazil became the next nation to produce postage stamps, issuing stamps made by
 P a g e | 13

its currency engraver in 1843. Various cantons in what later became Switzerland
also produced stamps in 1843. United States postage stamps (in five and ten cent
denominations) were first authorized by Congress in 1847 and came on the market
on July 1 of the same year. By 1860, more than 90 countries, colonies, or districts
were issuing postage stamps.
Most early stamps were of a single color—the United States, for example, did
not produce multicolored stamps until 1869, and they did not become common until
the 1920s. The penny black and other early stamps needed to be separated with a
scissors; perforated stamps did not appear until 1854 in England and 1857 in the
United States. However, though larger stamps are occasionally produced, the penny
black's original size, .75 by .875 inch (1.9 by 2.22 centimeters), has remained
standard.
Initially, stamps were manufactured by the same businesses that
provided a country with currency, or by a country's mint. Yet it soon became
apparent that printing stamps is unlike minting money in that the different paper
types call for different printing pressures. Consequently, printing stamps became a
discrete activity, though one still sometimes carried out by companies that made
currency. In ensuing years, methods of producing stamps mirrored the development
of modern printing processes. Today, stamp making processes utilize much of the
finest printing technology available.
In the United States, the decision to produce a stamp is
made by a Citizens' Stamp Advisory Committee, which meets regularly in
conjunction with staff from the Post Office. The committee is responsible for
determining what stamps will be produced, in what denominations, and at what time.
Suggestions for stamps come from throughout the country, although the committee
itself might recommend a particular design. Most frequently, however, there is a
large pool of recommendations with which to work. In some cases, suggestions are
accompanied by drawings and pictures which might form the basis for the stamp
being considered.
Once the committee decides that a particular stamp will be produced, it
commissions an artist to design it or modify a submitted design. It then decides,
primarily on the basis of workload, whether the stamp should be produced by the
Bureau of Engraving and
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The engraving method of intaglio printing begins with the creation of a master die on
which the design of the stamp is engraved, in reverse. The design is in the lowered
portion of the die—the raised portion will not be reproduced in the final product. This
is an exacting hand process, in which the engraver carefully cuts a mirror image of
the original drawing for the stamp.
The master die impression is then copied onto a transfer roll, and in turn onto a
printing plate. The impression on the plate is in the form of grooves rather than a
raised image. Next, the plate is fastened into the printing press and coated with ink,
and the appropriate paper is fed through the press.
Printing or by outside contractors, who have been used much more
extensively since the late 1980s. It's possible for a common stamp in great demand
(such as an everyday first class mail stamp) to be made by the Bureau of Engraving
and Printing and by several contractors. Currently, perhaps ten to fifteen American
firms are capable of manufacturing stamps that meet Post Office standards.
Specifications for the stamp, such as color, size, design, and even the printing
process itself are then drawn up in consultation with the original artist or designer. If
the stamp is to be contracted out, a "request for proposal" appears in the Commerce
Business Daily, a U.S. government publication which lists contracts available to non-
government firms. After the stamp is printed, samples will be sent to the International
Bureau of the Universal Postal Union in Switzerland, where they are marked as
samples (commonly perforated with a word such as "specimen") and then distributed
 P a g e | 15

to member nations to help postal workers recognize other countries' legitimate

postage.
In addition to requirements for the picture or design on a stamp, other
requirements, all of which can be met at a printing plant, are sometimes added to a
stamp's specification. The most common one is phosphor tagging, in which an
invisible mark that can be read only by a special machine is placed on a stamp. The
tagging facilitates the automated sorting of mail.
Other requirements might be for such things as printing the stamp on chalked paper
to prevent reuse of a stamp by cleaning or washing off a cancellation. When a
canceled stamp printed on chalked paper is wetted, the picture will blur as the
cancellation mark is wiped off, cuing postal workers to the fact that the stamp is no
longer valid.

 Raw Materials
Although stamps were originally printed on sheets of paper that were fed into
presses individually, the paper now used comes on a roll. The two kinds of paper
most commonly used to print stamps are laid and wove paper, the former with ribbed
lines and the latter without. While other nations use both types, the United States
presently uses only wove. Either laid or wove paper might feature watermarks, faint
designs that result from differences in the pressure applied to various parts of a roll
of paper during the production process. Commonly used in other counties,
watermarked paper has not been utilized in the United States since 1915.

 The Manufacturing process

At the printing plant, the process begins with the delivery of paper for stamps, with
the glue already applied to the back. Two printing processes are most often used in
making stamps, the intaglio process (which includes the gravure process), and the
offset process. It is not unusual, however, for a particular stamp's specifications to
call for the use of both methods.
Intaglio, perhaps the oldest means of producing stamps, is also the most time-
consuming. However, because this method creates stamps with more distinct
 P a g e | 16

images, the process has not been pushed aside by newer, faster, and less
expensive methods. Intaglio involves engraving, scratching, or etching an image
onto a printing plate, which in turn transfers that image onto paper. In one well-
known intaglio process, called gravure, the image is first transferred onto the plate
photographically, and then etched into the plate. This section, however, will focus on
an engraving process.

 Creating the master die

 The engraving method of intaglio begins with the creation of a "master

die" in which the design of the stamp is engraved, in reverse. The design
is in the lowered portion of the die—the raised portion of the die will not
be reproduced in the final product. This is an exacting hand process, in
which the engraver is carefully cutting a mirror image of the original
drawing for the stamp. It might be several weeks before the engraver is
satisfied that he or she has created the perfect duplicate.

 After the die has been completed, it is heated to harden the engraved
image. In the next step, the hardened intaglio is transferred to a transfer
roll, which consists of soft steel wrapped around a rod-shaped carrier, or
mandrel, and which resembles a shortened rolling pin. The transfer roll is
machine-pressed against the master die, and rocked back and forth until
the master die has created a relief impression on the transfer roll. At this
point, the relief is a positive impression (no longer in reverse). The
process is repeated until the desired number of reliefs has been created
on the transfer roll.
Preparing the printing plate
 Like the master die, the transfer roll is hardened by heating. It is then
pressed against a printing plate, leaving another relief, again in reverse,
on the printing plate. If there are several reliefs on a transfer roll, all can
be passed to the printing plate. Several printing plates can be made from
the same transfer roll if the decision is made to use more than one
 P a g e | 17

machine to produce a particular stamp. The impression on the plate is in

the form of grooves rather than a raised image.
 Once the plate is ready for use, it is fastened into the printing press and
coated with ink. Inking is done automatically by several processes
including spraying ink through small jets or moving an ink-covered roller
across a plate. The plate is then wiped by a blade called the doctor blade,
leaving ink only in the grooves.
 The plate then presses against the paper, leaving a positive impression of
the reverse image that was originally copied onto the master die.
 If more than one color is involved, separate colors are handled by a
process known as selective inking. A particular color of ink is applied by a
piece of hard rubber that comes in contact with only the section of the
stamp that is to receive that color. After the ink is applied in one area,
another piece of rubber, with another color for another area, is used to ink
another portion of the plate.

 Offset lithography

 The offset method of printing is less expensive than intaglio and can also
produce very fine results, and it is a common choice for many stamps. In
this method, a picture or design is first made photo chemically on an
aluminum plate. Once attached to the printing press, the plate is
alternately bathed in ink and water: the photochemical image gets ink,
while the non-image parts are dampened with water, which acts as a
repellent to the ink and ensures that only the image will be transferred to
the paper. Next, the plate presses against a rubber "blanket," which
carries a reverse image of the final picture. In turn, the rubber blanket
contacts the paper, producing the final positive image.
 P a g e | 18

In offset lithography, a picture or design is first made photo chemically on an

aluminum plate. Once attached to the printing press, the plate is alternately bathed in
ink and water: the photochemical image gets ink, while the non-image parts are
dampened with water, which acts as a repellent to the ink and ensures that only the
image will be transferred to the paper. Next, the plate presses against a rubber
'blanket,' which carries a reverse image of the final picture. In turn, the rubber
blanket contacts the paper, producing the final positive image.

 Perforation

 Perforations can be made either during the printing process by an

adjacent machine or, less commonly, by a separate machine afterwards.
In the first method, the sheet of paper is passed through a machine which
uses little pins to punch the perforation holes through the paper in a
horizontal and vertical grid. After pushing through the paper, the pins
meet a matching metal indentation on the other side. After being
perforated, the stamps move out of the press. In the other method of
producing perforations, called rouletting, a wheel similar to a pizza cutter
but with pins is rolled across one side of the stamped paper after it has
been removed from the printing press, laying down a row of holes.
Though originally a hand-operation, this method of perforation is now
automated.
 P a g e | 19

 Quality Control
Stamps are inspected at every stage of the printing process, by the people
who are running the stamps and by inspectors whose only responsibility is to
observe the process and remove errors before the stamps proceed to the next step.
Printing machines are hugely complex, and errors in the printing process are a fact
of life. Misfed paper clogged inking apparatus, variations in pressure, changes in ink
quality, incorrectly adjusted mechanisms, and a host of other problems can be
minimized but not always eliminated. Even changes in the humidity of the pressroom
can affect the press and the paper enough to produce less-than-perfect results.
Several of the most spectacular errors of the past occurred because presses were
manually fed; in other words, individual sheets of paper were inserted into the press
by hand. If a sheet of paper required an impression from a second press (to add a
second color), and the sheet was turned accidentally, the resulting stamps featured
misplaced blotches of color. This type of error does not occur today because presses
are roll-fed: rather than being fed into a press sheet by sheet, paper is fed in from a
continuous roll.
Most errors are detected, and the flawed stamps destroyed, under tight security
controls in the printing plant. Enough errors slip through, however, to make the
collecting of "error stamps" an interesting specialty for some stamp collectors.

 METOD OF PRINTING PRESS

 Offset press

Offset printing is a widely used printing technique where the inked image is
transferred (or "offset") from a plate to a rubber blanket, then to the printing surface.
When used in combination with the lithographic process, which is based on the
repulsion of oil and water, the offset technique employs a flat (plan graphic) image
carrier on which the image to be printed obtains ink from ink rollers, while the non-
printing area attracts a film of water, keeping the non-printing areas ink-free.
 P a g e | 20

Web-fed offset

Offset printing is a commonly used printing technique where the inked image is
transferred (or "offset") from a plate to a rubber blanket, then to the printing surface.
When used in combination with the lithographic process, which is based on the
repulsion of oil and water, the offset technique employs a flat (planography) image
carrier on which the image to be printed obtains ink from ink rollers, while the non-
printing area attracts a water-based film (called "fountain solution"), keeping the non-
printing areas ink-free.

Development of the offset press came in two versions: in 1875 by Robert Barclay of
England for printing on tin, and in 1903 by Ira Washington Rubble of the United
States for printing on paper.

SIX COLOR MACHINE

 P a g e | 21

Currently, most books and newspapers are printed using the technique of offset
lithography. Other common techniques include:

 Flexography used for packaging, labels, newspapers.

 hot wax dye transfer
 Inkjet used typically to print a small number of books or packaging, and also
to print a variety of materials from high quality papers simulate offset printing,
to floor tiles; Inkjet is also used to apply mailing addresses to direct mail
pieces.
 Laser printing mainly used in offices and for transactional printing (bills, bank
documents). Laser printing is commonly used by direct mail companies to
create variable data letters or coupons, for example.
 Pad printing popular for its unique ability to print on complex 3-dimensional
surfaces.
 Relief print, (mainly used for catalogues).
 Rotogravure mainly used for magazines and packaging.
 Screen-printing from T-shirts to floor tiles.

 History OF Offset printing

Lithography was initially created to be a low cost method of reproducing

artwork. This printing process was limited to use on flat, porous surfaces because
the printing plates were produced from limestone. Tin cans were popular packaging
materials in the 19th century, but transfer technologies were required before the
lithographic process could be used to print on the tin.

The first rotary offset lithographic printing press was created in England and
patented in 1875 by Robert Barclay. This development combined mid-19th century
transfer printing technologies and Richard March Hoe’s 1843 rotary printing press—a
press that used a metal cylinder instead of a flat stone. The offset cylinder was
covered with specially treated cardboard that transferred the printed image from the
stone to the surface of the metal. Later, the cardboard covering of the offset cylinder
was changed to rubber, which is still the most commonly used material.

As the 19th century closed and photography captured favor, many lithographic firms
went out of business. Photoengraving, a process that used halftone technology
instead of illustration, became the leading aesthetic of the era. Many printers,
including Ira Washington Rubble of New Jersey, were using the low-cost lithograph
process to produce copies of photographs and books. Ruble discovered in 1901—by
forgetting to load a sheet—that when printing from the rubber roller, instead of the
metal, the printed page was clearer and sharper. After further refinement, the Potter
Press printing Company in New York produced a press in 1903. By 1907 the Ruble
offset press was in use in San Francisco.
 P a g e | 22

The Harris Automatic Press Company also created a similar press around the same
time. Charles and Albert Harris modeled their press “on a rotary letter press
machine,” (“Short History of Offset Printing”).

 Present day

Compared to other printing methods, offset printing is best suited for cost-effectively
producing large volumes of high quality prints in an economically sound manner that
requires little maintenance.

 Applications

Offset lithography is one of the most common ways of creating printed matter. A few
of its common applications include: newspapers, magazines, brochures, stationery,
and books.

Many modern offset presses use computer to plate systems as opposed to the older
computer to film workflows, which further increases their quality.

 Advantages

Advantages of offset printing compared to other printing methods include:

 Consistent high image quality. Offset printing produces sharp and clean
images and type more easily than letterpress printing because the rubber
blanket conforms to the texture of the printing surface.
 Quick and easy production of printing plates.
 Longer printing plate life than on direct litho presses because there is no
direct contact between the plate and the printing surface. Properly developed
plates running in conjunction with optimized inks and fountain solution may
exceed run lengths of a million impressions.
 Cost. Offset printing is the cheapest method to produce high quality printing in
commercial printing quantities.

 Disadvantages

Disadvantages of offset printing compared to other printing methods include:

 Slightly inferior image quality compared to rotogravure or photogravure

printing.
 Propensity for anodized aluminum printing plates to become sensitive (due to
chemical oxidation) and print in non-image/background areas when
developed plates are not cared for properly.
 Time and cost associated with producing plates and printing press setup. As a
result, very small quantity printing jobs are now moving to digital offset
machines.
 P a g e | 23

 Types
 Photo offset

Side view of the offset printing process. Multiple ink rollers are used to
distribute and homogenize the ink.

The most common kind of offset printing is derived from the photo offset process,
which involves using light-sensitive chemicals and photographic techniques to
transfer images and type from original materials to printing plates.

In current use, original materials may be an actual photographic print and typeset
text. However, it is more common with the prevalence of computers and digital
images that the source material exists only as data in a digital publishing system.

Offset litho printing on to a web (reel) of paper is commonly used for printing of
newspapers and magazines for high speed production.

How ink is transferred from the ink duct to the paper has several steps.

 Ink duct roller delivers ink from the ink duct to the ink pyramid.
 The drop roller transfers ink from duct roller to distribution roller. It is never in
contact with both rollers at the same time.
 The distribution rollers evenly distribute the ink. The first distribution roller
picks up the ink from driving rollers, and the last distribution rollers transfer the
ink to the form rollers.
 The transfer rollers transfer ink between the ink-absorbing and ink-delivering
driving rollers.
 Driving rollers roll against the distribution rollers and either absorb or deliver
ink, depending on their placement.
 Ink form rollers transfer ink from the last distribution rollers on to the printing
plate.
 The printing plate transfers the ink to the offset cylinder(typically called
blanket cylinder) usually covered with a rubber 'blanket'.
 The paper is then pressed against the blanket cylinder by the impression
cylinder,

 Types of paper feed

 Sheet-fed litho

"Sheet-fed" refers to individual sheets of paper or paperboard being fed into a press.
A lithographic ("litho" for short) press uses principles of lithography to apply ink to a
printing plate, as explained previously. Sheet-fed litho is commonly used for printing
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of short-run magazines, brochures, letter headings, and general commercial

(jobbing) printing.

 Web-fed litho

"Web-fed" refers to the use of rolls (or "webs") of paper supplied to the printing
press. Offset web printing is generally used for runs in excess of 10 or 20 thousand
impressions. Typical examples of web printing include newspapers, newspaper
inserts/ads, magazines, catalogs, and books. Web-fed presses are divided into two
general classes: "Cold" or "Non-Heat set," and "Heat set" offset web presses, the
difference being how the inks that are used dry. Cold web offset printing dries
through absorption into the paper, while heat set utilizes drying lamps or heaters to
cure or "set" the inks. Heat set presses can print on both coated (slick) and uncoated
papers, while coldest presses are restricted to uncoated paper stock, such as
newsprint. Some coldest web presses can be fitted with heat dryers, or ultraviolet
lamps (for use with uv-curing inks). There is also another possibility of adding a drier
in a cold-set press and making it as a semi-commercial press. It is a concept where
a newspaper can print color pages in heat set and BW pages in coldest.

 Web press v. sheet-fed (photo offset)

Sheet-fed presses offer several advantages, because individual sheets are fed
though, a large number of sheet sizes and format sizes can be run through the same
press. In addition, waste sheets can be used for make-ready which allows for lower
cost make-readies, so that good paper is not wasted while setting up the press, for
plates & inks (waste sheets do bring some disadvantages as often there are dust,
offset powder particles that transfer on to the blankets and plate cylinders, thereby
creating imperfections on the printed sheet in the form of "hickies").

Web-fed presses, on the other hand, are much faster than sheet-fed presses, they
are roll fed (no sheets, and most rolls come in 17" & 34" sizes, and weigh up to
1000 lbs) The speed of the web press is in excess of 20,000 cutoffs per hour. Their
speed makes them ideal for large runs such as newspapers or magazines. However,
web-fed presses have a fixed cut-off, unlike other presses such as rotogravure or
flexographic presses.

 Types of commercial offset processes

 Perfecting press

A perfecting press, also known as a duplex press, is one that can print on both sides
of the paper at the same time (Bruno, Romano, and Riordan 137). Web and sheet-
fed offset presses are similar in that many of them can also print on both sides of the
paper in one pass, making it easier and faster to print duplex.

 Offset duplicators
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Small offset lithographic presses that are used for fast, good quality reproduction of
1- and 2-color copies in sizes up to 12”X18”. (Romano, & Riordan 139–141)

Offset duplicators are made for fast and quick printing jobs; therefore have faster
make-readies and turn-around time, printing up to 12,000 impressions per hour.

They are able to print business forms, letterheads, labels, bulletins, postcards,
envelopes, folders, reports, and sales literature.

 Sheetfed offset

In sheet-fed offset, “the printing is carried out on single sheets of paper as they are
fed to the press one at a time.” Sheet-fed presses use mechanical registration to
relate each sheet to one another to ensure that they are reproduced with the same
imagery in the same position on every sheet running through the press. (“What is
Offset Printing”)

 Process

The actual process of printing is quite involved. One of the most important functions
in the process is Pre-press Production. This basically the front end of things actually
printing and makes sure that all files are correctly processed to be printed. This
includes converting to the proper CMYK, finalizing the files, and creating plates for
each color of the job to be run on the press. The sheet fed press consists different
systems that complete the actual process; feeder system, printing system,
inking/dampening system, and the delivery system.

 Feeder system

The feeder system is responsible for making sure paper runs through the press
correctly.
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FEEDER SYSTEM

This is where you load the substrate and then correctly set up the system to the
certain specifications of the substrate to the press. (DeJidas & Destree, 2005, p. [55-
57])

 Printing/inking system

The Printing Unit consists of many different systems. The dampening system is used
to apply dampening solution to the plates with water rollers. The inking system uses
rollers to deliver ink to the plate and blanket cylinders to be transferred to the

INK FEED SYSTEM

substrate. The plate cylinder is where the plates containing all of the imaging are
mounted. Finally the blanket and impression cylinders are used to transfer the image
to the substrate running through the press. (DeJidas & Destree, 2005, p. [143])

 Delivery system
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The delivery system is the final destination in the printing process while the paper
runs through the press. Once the paper reaches delivery, it is stacked for the ink to
cure in a proper manner. This is also where you can check on sheets to make sure
they have proper ink density and registration.

DELIVERY GATE

 Blanket-to-blanket

A printing method in which there are two blanket cylinders through which a sheet of
paper is passed and printed on both sides. (Commercial color offset printing – a
compendium of commercial printing terminology)

Blanket-to-blanket presses are considered a perfecting press because they print on

both sides of the sheet at the same time. Since the blanket-to-blanket press has two
blanket cylinders, making it possible to print on both sides of a sheet, there is no
impression cylinder. The opposite blanket cylinders act as an impression cylinder to
each other when print production occurs. There are also two plate cylinders on the
press.

 Blanket-to-steel

A printing method similar to a sheet offset press; except that the plate and cylinder
gaps are very narrow. (Romano & Riordan 139–141)
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BLANKET-GREEN COLOUR

Blanket-to-steel presses are considered one-color presses. In order to print the

reverse side, the web is turned over between printing units by means of turning bars.
(Romano & Riordan 139–141)

The method can be used to print business forms, computer letters, and direct mail
advertising.

 Variable-size printing

A printing process that uses removable printing units, inserts, or cassettes for one-
sided and blanket-to-blanket two-sided printing. (Romano, & Riordan 139–141)

 Keyless offset

Keyless offset is a printing process that is based on the concept of using fresh ink for
each revolution by removing residual inks on the inking drum after each revolution.
(Romano & Riordan 139–141) It is suitable for printing newspapers.

 Types of plate making

Generally, “the plates used in offset printing are thin,” and are mostly made of
aluminum, though sometimes can be made of multimetal, paper, or plastic (Kipphan
209).

 Polyester plates
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Polyester plates can be used in place of aluminum plates for smaller formats or
medium quality jobs, “as their dimensional stability is lower” (Kipphan 209).

 Types of plate printing processing system

 Deep bath system.

 Shower system.

 Deep bath system: It contains six unit:

 Input six unit

 Developing unit
 Rinsing unit
 Gummins unit
 Drying unit
 Collection unit

 Shower type system: It contains two system:

 Two roller type system, Three roller type system.

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Computer to Plate (CTP)

Computer to Plate (CTP) is a newer technology that allows the imaging of metal or
polyester plates without the use of film. Eliminating the stripping, compositing, and
traditional plate making processes, CTP revolutionized the printing industry and led
to reduced prepress times, lower costs of labor, and improved print quality.

Most CTP systems used thermal CTP as opposed to violet CTP, though both
systems are effective, depending on the needs of the printing job. Thermal CTP does
have the advantage of extremely high quality, but Violet CTP does cost significantly
less. Thermal plates are generally used for longer runs, while Violet CTP is
employed for shorter runs, and popular with 2-up and 4-up applications (Bruno,
Romano, and Riordan 126).

Thermal CTP has the added bonus of utilizing binary exposure, which limits the risk
of under or overexposure, and makes it possible to work under yellow light (Bruno,
Romano, and Riordan 126).

Thermal CTP involves the use of thermal lasers to expose and/or remove areas of
coating while the plate is being imaged. This depends on whether the plate is
negative, or positive working. These lasers are generally at a wavelength of 830
nanometers, but vary in their energy usage depending on whether they are used to
expose or ablate material. Violet CTP lasers have a much lower wavelength, 405–
410 nanometers. Violet CTP is “based on emulsion tuned to visible light exposure,”
(Bruno, Romano and Riordan 126). The general trend of platesetters has been to
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move toward coatings whose success on press is independent of post imaging

chemical bath processing.

Types of plate processing

 Types of chemicals used

 Paste inks for offset litho

Offset printing uses inks that, compared to other printing methods, are highly
viscous. Typical inks have a dynamic viscosity of 40–100 Pa·s.

There are many types of paste inks available for employment in offset lithographic
printing and each have their own advantages and disadvantages. These include
heat-set, cold-set, and energy-curable (or EC), such as ultraviolet- (or UV-) curable,
and electron beam- (or EB-) curable. Heat-set inks are the most common variety and
are "set" by applying heat and then rapid cooling to catalyze the curing process.
They are used in magazines, catalogs, and inserts. Cold-set inks are set simply by
absorption into non-coated stocks and are generally used for newspapers and books
but are also found in insert printing and are the most cost-conscious option. Energy-
curable inks are the highest-quality offset litho inks and are set by application of light
energy. They require specialized equipment such as inter-station curing lamps, and
are usually the most expensive type of offset litho ink.

 Inks
 Letterset

Letterset inks are mainly used with offset presses that do not have dampening
systems and uses imaging plates that have a raised image. (Romano, & Riordan
160)
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PRINTING INK

 Waterless

Waterless inks are heat-resistant and are used to keep silicone-based plates from
showing toning in non-image areas. These inks are typically used on waterless
Direct Imaging presses. (Romano & Riordan 160)

 Single fluid

Single Fluid Inks are newer ink that uses a process allowing lithographic plates on a
lithographic press without using a dampening system during the process. (Romano &
Riordan 160)

 Ink/water balance

Ink and water balance is an extremely important part of offset printing. If ink and
water are not properly balanced, you can end up with many different problems such
as scrumming, trapping, and ink density issues. With the proper balance, the job will
have the proper ink density and should need little further adjustment.

 Fountain solution

Fountain solution is the water-based (or "aqueous") component in the lithographic

process that cleans the background area of the plate in order to keep ink from
depositing (and thus printing) in the non-image (or "white") areas of the paper.
Historically, fountain solutions were acid-based and made of gum Arabic, chromates
and/or phosphates, and magnesium nitrate.

While the acid fountain solution has come a long way in the last several decades,
neutral and alkaline fountain solutions have also been developed. Both of these
chemistries rely heavily on surfactants/emulsifiers and phosphates and/or silicates to
provide adequate cleaning and desensitizing, respectively. Since about 2000,
alkaline-based fountain solutions have started becoming less common due to the
inherent health hazards of high pH and the objectionable odor of the necessary
microbiogical additives.
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Acid-based fountain solutions are still the most common variety and yield the best
quality results by means of superior protection of the printing plate, lower dot gains,
and longer plate life. Acids are also the most versatile, capable of running with all
types of offset litho inks. However, because these products require more active
ingredients to run well than do neutrals and alkaline, they are also the most
expensive to produce. That said, neutrals and, to a lesser degree, alkaline are still an
industry staple and will continue to be used for most newspapers and many lower-
quality inserts.

In recent years alternatives have been developed which do not use fountain
solutions at all (waterless printing).

 Identification

Every printing technology has its own mark so has the offset printing. In text
reproduction the type edges are sharp and have clear outlines (see following
picture). The paper surrounding the ink dots is usually unprinted. The halftone dots
are always irregular and blurry though there are different screening methods (AM
and FM).

 In industry

Offset lithography became the most popular form of commercial printing in the 1950s
("Offset Printing"). Subsequent improvements in plates, inks, and paper enhanced
the technology and maximized its superior production speed and plate durability.
Today, lithography is the dominant printing technology in the US, and most
lithography is printed as offset lithography.

Today, offset lithography is "responsible for over half of all printing using printing
plates" (Bruno, Romano and Riordan 137). The quality of the prints made is
consistently high, and the volume of prints created for their respective cost makes
commercial offset lithography very efficient for businesses, especially when many
prints must be created quickly.

 Web offset

A high run, speed printing press that uses rolls of paper rather than individual sheets
(Spectrum Printers).

Web Offset Presses are beneficial in long run printing jobs, typically press runs that
exceed 10 or 20 thousand impressions. Speed is a huge factor when considering
turnaround time for press production; some web presses print at speeds of 3,000
feet per minute or faster. In addition to the benefits of speed and possible faster
turnaround times, some web presses have the inline ability to print, but also cut,
perforate, and fold.
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 Reference:

www.google.com

www.hiscan.com

www.printing processes.com

www.offset printing.com

Printing processes book.

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 Conclusion:
 After working on this project, I known about technology of
SUBMERSIBLE PUMP . I am also known about How works on it.

 I am also thankful of MUKUND NGINEERING industry for

satisfactoriy guide about their machines & how that works. I am also
thankful my project related shri MANOJ N. PATEL.

.
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