Graphic Designers' Guide to Flexographic Labels

This guide has been prepared to give graphic designers some basic rules to follow when preparing artwork for labels that are to be printed using the Flexographic (flexo) printing process.

Following these simple guidelines will dramatically improve the printability of your job. It will also help the designer, the customer and Label Innovation Inc. (LINC) to work as partners. The end result will be first quality labels and high customer satisfaction.

1. Notes to the graphic designer

All brands of graphic design software are geared to the offset printing process. Offset tolerances are tighter and also allow a greater degree of artistic freedom than the flexo process can tolerate. However, flexo can equal offset in most areas and today's advances in flexo plates are producing quality that rivals offset, if just a few things are taken into consideration.

2. The Flexographic Process

Flexo printing plates are made with a raised image while offset plates use a flat or planographic plate to carry the ink. As a result, ink dots in halftones; process color and screens are carried on the tips of the raised cones or pyramids on the flexo plate. This places a limit on the size of the dot that flexo can hold. Another flexo factor is the register tolerance color to color. The raised softer plate, roll to roll (web) printing method and spongy self adhesive paper constructions define these tolerance limits.

3. Electronic Art Requirements

Electronic artwork is preferred; however, negative film and/or black and white camera-ready art are also accepted for some types of work. See Guidelines for Film and Black and White Preparation Materials for Flexographic Labels (below).

Platform

Macintosh and Windows files accepted. Please send a hardcopy or PDF of your art for comparison.

Software

Adobe Illustrator v. 10
Adobe Photoshop v. 7 (TIFF or EPS)
Adobe Pagemaker v. 7
Corel Draw v. 11 (Windows only)
Freehand v. 10
Indesign v.2
QuarkXpress v. 5
QuarkPassport - Ensure files are saved as "single language document"

Note: Word processing programs do not allow us to print sharp, high quality labels.

Compressing

For Macintosh use Stuff-it, Disc Doubler or .sea and for Windows use WinZip or Zip it

Media

CD-ROM
DVD
3.5" diskette
Jaz or Zip disk
Syquest EZ 135 MB, EZ 230 MB
Optical Disc 600 MB, 1.3 GB, 2,6 GB
E-mail attachment
Line Screen
Maximum 175-line screen for optimum print quality.

Resolution

300 dpi minimum, 600 + dpi preferred for sharpest image

Trapping

Leave all trapping to be done by Label Innovation. Flexographic printing requires larger spreads than offset. Dead fits colour to colour are not possible to hold on press.

Colour

When a colour is opaque enough to overprint a background colour, do not drop out the background. When in doubt about colour opacities, please consult Label Innovation for advice. Be aware when using graduated screen backgrounds, dots in the 30% to 60% range have greater gain on press than outside that range. Please leave your files totally accessible for Label Innovation to do necessary adjustments. Spot colour should be from Pantone (PMS) approved charts.

Please use CMYK not RGB, colour separation is not necessary, however, their locations and PMS equivalent should be clearly marked. If PMS equivalent please send a colour sample. Single colour files can be saved as such.

Scans

All scans should be in "high resolution dot" processed in CMYK not RGB.

Screen Angles

Best screen angles are Cyan 7.5, Magenta 37.5, Yellow 82.5 and Black 67.5 degrees.

Text

Never have text made up of process colour. Please avoid having text as a drop out in a process colour background, if it has to be, please make it a large, open style and bold.

Bleeds

Extend bleeds 1/8" beyond the die cut edge of the label.

Image

Please keep the printed image 1/8" away from the die cut edge of the label.

Sending Artwork

A colour proof and separated black and white copy or PDF file must always accompany all electronic files. Colour proofs (such as Chromalin or equivalent system) are only an approximation of the final printed image. Please always supply complete information about your files (i.e. program, version, special fonts, imbedded file, etc.)
Images: please send a separate file for each placed or imported image (i.e. photos, barcodes, illustrations, etc.)
Fonts: please include all fonts (i.e. regular, bold, italic, etc.)
Please be sure all files can be altered by Label Innovation LINC for necessary flexo changes.

Sending Files

Option 1:

E-mail electronic file to mailbox@labelinnovation.com along with a PDF version of the file for cross reference.

Option 2:

Courier or mail to:

Label Innovation Inc
Client Services
2714 Fenton Road
Ottawa ON
K1T 3T7

4. Guidelines for Film or Black and White Preparation Materials for Flexographic Labels

Dot size: Minimum 5%, but 10% is preferred
Line screen: Minimum 133-line screen, maximum 150-line screen
Negatives: to be made wrong reading emulsion side down
Chokes and spreads for lines and solids: leave to be done by Label Innovation.
Provision of black and white preferred for line and solid work
Colour proofs (colour keys, chromalin etc.) required for multiple colour jobs
Screen Angles: Best screen angles are Cyan 7.5, Magenta 37.5, Yellow 82.5 and Black 67.5 degrees.
Open screens throughout label as much as possible to achieve colour (40% or less, unless a solid)
Avoid 30% to 60% screen range.

If you have any questions about these requirements please contact us.