Education, Knowledge and Know-how
Everybody wants to reach a production process that is repeatable and of improved quality.
One can do this by identifying the variables within the system and understanding their interactions in printing.
This objective is attainable via educational activities in order to improve users technical know-how and allow a continuous update to the latest production techniques in flexography.
A significative experience, gained over 30 years of activity, allows flexo•expert to be a competent partner to rely on, in case of educational, calibration and consultancy requirements within the flexographic printing process for packaging production.
Certified education
The educational activities offered by flexo•expert are supported by the 30+ years of experience of Stefano d’Andrea within the flexographic industry.
Stefano is an industrial graphic expert who was acknowledged as Certified Implementation Specialist according to the FIRST (Flexographic Image Reproduction Specifications & Tolerances) program of FTA, the American Flexographic Technical Association.
This important acknowledgement is given after the completion of 3 levels of in-depth training on the flexographic process that covers all aspects, starting from the communication between the customer, the prepress and the printing phases, up to the optimization and characterization methods of the flexographic printing system.
A winning method
Flexographic Image Reproduction Specifications & Tolerances (FIRST) supports the methodical approach to process control, optimization, fingerprinting, characterization and process improvement as outlined in CGATS TR 012-2003 (Graphic Technology – Color Reproduction and Process Control for Packaging Printing).
While each organization may use its own workflow based upon its specific needs, there are certain fundamentals universal to the flexographic printing process that must be known for the system to be effective and produce quality and economic satisfaction.
With a firm understanding and application of this methodology, and thanks to the educational program offered by flexo•expert, flexographers can:
- identify potentially troublesome issues;
- benchmark press performance;
- utilize statistical analysis to maintain optimal conditions;
- perform accurate device calibrations;
- identify improvement opportunities;
- preserve stable conditions for repeatable results
All with the end result of satisfactorily reproducing the graphic design that was commissioned.
The training activities offered by flexo•expert comply with the FTA FIRST method, with the ISO standards relevant to the flexographic process and with the Guidelines and specifications suggested by Atif (www.atif.it) to guarantee a level of professionalism appropriate to the modern needs of packaging printing in flexography.
Training courses
Educational and technical training activities are addressed to packaging printers (flexible packaging, labels and corrugated), platemaking companies, repro studios and graphic designers, manufacturers and distributors of printing presses and related technologies, graphic schools and trade associations, brand owners.
All educational activities are conducted by Stefano d’Andrea, graphic arts expert and FIRST Implementation Specialist, Level III (Certificate #ISC0183), certified by the Flexographic Technical Association (FTA), the world’s leading professional society dedicated to the advancement of the flexographic printing process.
Program of activities covers the following topics:
Basic Training (6 hours)
Ideal for a good introduction to the fundamentals of the flexographic process, touching the most relevant subjects from the printing group components to elements of prepress and system calibration.
Advanced Training (18 hours)
Dedicated to the advanced users who need to dig into more technical information with detailed description of every component in the printing group and their variables. Our interaction with color reproduction, from perception, through measurement and management in prepress. And finally a complete step-by-step description of the system calibration with optimization, fingerprint and characterization.
Complete Training (24 hours)
The complete package, includes all subjects of the Advanced course plus a deeper comparison between different printing technologies and evolution of the flexographic process. A full training about the platemaking process and its calibration is also included.
Detailed Program of Courses
Legend to symbols
⬤ = full subject covered during session
◒ = subject covered in essential concepts
Components of the flexographic printing group | |||
Flexography among packaging printing systems | Base | Advanced | Complete |
Packaging among printed products | ◒ | ⬤ | |
Printing systems and printing forms | ◒ | ⬤ | |
Inking restraints of different systems | ⬤ | ||
Ink transfer and graphic reproduction | ◒ | ⬤ | |
Press structure in different printing systems | ⬤ | ||
Substrates used in the various printing systems | ⬤ | ||
Packaging products reproducible in different printing system | ⬤ | ||
Inks characteristics | ⬤ | ||
Recognize the printing technology on printed products | ⬤ | ||
Comparison of printing systems | ◒ | ⬤ | |
Evolution of flexography | Base | Advanced | Complete |
The origins of the flexographic system | ⬤ | ||
Evolution of the inking system | ⬤ | ||
Flexographic presses structures | ⬤ | ||
The anilox roller | Base | Advanced | Complete |
Understanding cell count and volume | ◒ | ⬤ | ⬤ |
Evolution of anilox rolls | ⬤ | ⬤ | |
Laser engraving on ceramic | ◒ | ⬤ | ⬤ |
Construction, characteristics and tolerances | ⬤ | ⬤ | |
Comparison between different angles and engraving geometries | ◒ | ⬤ | ⬤ |
Engraving volumes and ideal ratios | ◒ | ⬤ | ⬤ |
Anilox-to-plate ratio | ◒ | ⬤ | ⬤ |
Main defects due to excess ink | ◒ | ⬤ | ⬤ |
How to measure anilox volume | ⬤ | ⬤ | |
Cleaning systems and maintenance | ◒ | ⬤ | ⬤ |
Ink metering in flexography | Base | Advanced | Complete |
Ink metering systems | ◒ | ⬤ | ⬤ |
Characteristics of the doctor blade | ◒ | ⬤ | ⬤ |
Metering angle | ◒ | ⬤ | ⬤ |
Metering system components and characteristics | ⬤ | ⬤ | |
Usage suggestions | ◒ | ⬤ | ⬤ |
Flexographic ink | Base | Advanced | Complete |
Types of ink | ◒ | ⬤ | ⬤ |
Comparison of solvent and water | ◒ | ⬤ | ⬤ |
Curable inks | ◒ | ⬤ | ⬤ |
Concentration and opacity | ◒ | ⬤ | ⬤ |
Pigments and Color Index | ⬤ | ⬤ | |
Types of resins and characteristics | ⬤ | ⬤ | |
Solvents and dilution | ⬤ | ⬤ | |
The pH in water based inks | ⬤ | ⬤ | |
Typical additives and their functions | ⬤ | ⬤ | |
Viscosity and control | ⬤ | ⬤ | |
Determine the volume of ink needed | ◒ | ⬤ | ⬤ |
Ink formulation | ◒ | ⬤ | ⬤ |
The flexographic printing form | Base | Advanced | Complete |
Main features | ◒ | ⬤ | ⬤ |
Thickness, relief and hardness | ◒ | ⬤ | ⬤ |
Creating a relief printing image | ◒ | ⬤ | ⬤ |
Flat top or round top | ◒ | ⬤ | ⬤ |
Measurement of printing elements on the plate | ◒ | ⬤ | ⬤ |
Cleaning and compatibility with solvents | ⬤ | ⬤ | |
Plate mounting and adhesive tapes | Base | Advanced | Complete |
Plate mounting | ◒ | ⬤ | ⬤ |
Principle and structure of double-sided cushion tapes | ◒ | ⬤ | ⬤ |
How do you make impressions on press | ⬤ | ⬤ | |
Thicknesses and tolerances | ⬤ | ⬤ | |
Suggestions for the use of double-sided tapes | ⬤ | ⬤ | |
Cylinders and sleeves for plate mounting | Base | Advanced | Complete |
From gears to gearless | ⬤ | ⬤ | |
Where printing takes place | ◒ | ⬤ | ⬤ |
External diameter and plate compression | ◒ | ⬤ | ⬤ |
Substrates | Base | Advanced | Complete |
Classification of substrates and their use | ◒ | ⬤ | ⬤ |
Surface tension | ◒ | ⬤ | ⬤ |
Paper and Corrugated cardboard | ⬤ | ⬤ | |
Web tension | ◒ | ⬤ | ⬤ |
Perception, reproduction, measurement and color management | |||
Principles of graphic reproduction | Base | Advanced | Complete |
From live image to printed reproduction | ◒ | ⬤ | ⬤ |
Halftone and resolution of the human eye | ◒ | ⬤ | ⬤ |
Resolution of devices in the production flow | ⬤ | ⬤ | |
Types of screening AM and FM | ⬤ | ⬤ | |
Color and perception | Base | Advanced | Complete |
Perception and characteristics of light | ⬤ | ⬤ | |
Color modes, additive and subtractive synthesis | ⬤ | ⬤ | |
The color of light | ⬤ | ⬤ | |
Viewing and lighting conditions | ◒ | ⬤ | ⬤ |
Behaviors of the human eye | ⬤ | ⬤ | |
Color measurement | Base | Advanced | Complete |
Describe color with mnodels (Lab, LCh) | ⬤ | ⬤ | |
Understanding and measuring density | ◒ | ⬤ | ⬤ |
Area coverage and dot % | ◒ | ⬤ | ⬤ |
Settings of densitometer and spectrophotometer | ◒ | ⬤ | ⬤ |
The color difference (Delta E) | ◒ | ⬤ | ⬤ |
Color management | Base | Advanced | Complete |
Color management principles, gamut and profiles | ⬤ | ⬤ | |
Color conversion | ⬤ | ⬤ | |
Four-color separation and construction of the profiles | ⬤ | ⬤ | |
Output intents, generic and specific conditions | ◒ | ⬤ | ⬤ |
Color is managed in the press room | ◒ | ⬤ | ⬤ |
The role of design | Base | Advanced | Complete |
Use of special colors | ◒ | ⬤ | ⬤ |
Guidelines for the reproduction of text and lines | ⬤ | ⬤ | |
Guidelines for the traps | ⬤ | ⬤ | |
Guidelines for linescreen settings | ⬤ | ⬤ | |
Guidelines for bar codes | ⬤ | ⬤ | |
The role of prepress | Base | Advanced | Complete |
Calibration and compensation curves | ◒ | ⬤ | ⬤ |
Prepare a job for flexo printing | ⬤ | ⬤ | |
Color management methods (ISO 10128) | ⬤ | ⬤ | |
Color conversion with Device Link profiles | ◒ | ⬤ | ⬤ |
The management of special and spot colors | ◒ | ⬤ | ⬤ |
Beyond the four-color process: 6, 7 colors, EGP | ⬤ | ⬤ | |
Color traps | ⬤ | ⬤ | |
Full plate layout and plate distortion | ◒ | ⬤ | ⬤ |
Contract color proof | ⬤ | ⬤ | |
Plate making | Base | Advanced | Complete |
Plate making technologies | ⬤ | ||
Analog and digital systems | ⬤ | ||
The photopolyerization process | ⬤ | ||
Calibration of the platemaking process | ⬤ | ||
Oxygen and polymerization: effects on the plate | ⬤ | ||
Methods to obtain flat-top plates | ⬤ | ||
CtP calibration: bump curve | ⬤ | ||
Direct laser engraving systems | ⬤ | ||
Quality, reference standards and calibration of the printing system | |||
Perceived quality and measured calibration | Base | Advanced | Complete |
We have always done in this way | ⬤ | ⬤ | |
Print linescreen and quality | ⬤ | ⬤ | |
Contrast, dotgain and quality | ⬤ | ⬤ | |
Print density and quality | ⬤ | ⬤ | |
Fundamental concepts and approach to calibration | ◒ | ⬤ | ⬤ |
Description of the calibration phases | ◒ | ⬤ | ⬤ |
ISO standards and reference specifications | Base | Advanced | Complete |
ISO 12647-6 – flexographic printing | ⬤ | ⬤ | |
ISO 20654 – SCTV | ⬤ | ⬤ | |
ISO 15339 – printing with different technologies, CRPC | ⬤ | ⬤ | |
ISO 10128 – color adjustment methods | ⬤ | ⬤ | |
Optimization | Base | Advanced | Complete |
Purpose and variables to be optimized | ◒ | ⬤ | ⬤ |
Uniformity and ink laydown | ⬤ | ⬤ | |
Tonal curves and compensation | ⬤ | ⬤ | |
Conventional, hybrid screens and minimum dot management | ⬤ | ⬤ | |
Optimize the roller inventory with the band anilox roller | ◒ | ⬤ | ⬤ |
Fingerprint and process control | Base | Advanced | Complete |
Purpose and variables to be checked | ◒ | ⬤ | ⬤ |
Graphic elements to be used in the test | ⬤ | ⬤ | |
The screen angles | ⬤ | ⬤ | |
The calibration with gray balance | ⬤ | ⬤ | |
Statistical approach and control charts | ◒ | ⬤ | ⬤ |
Characterization and improvement | Base | Advanced | Complete |
Purpose and variables to be verified | ◒ | ⬤ | ⬤ |
Considerations on the characterization process | ⬤ | ⬤ | |
From characterization data to profiles, to control data | ◒ | ⬤ | ⬤ |