Artwork Manual for combibloc and combifit

54 Pages·2012·7.41 MB·English

Gravure
Artwork Manual
for Rotogravure Printing
Edition: EN V4 | Status February 2016
Introduction
Contents 01
Introduction 02
Carton Structure 03
The Printing Technique 04
The Filling Process 05
Workflow 06
Working with the Keylines
The Structure of the combibloc and combifit Lay-
outs 07
The Bottom Section of the Carton 10
The Bottom Section - Cross-Section of Formats 11
The Carton Top Panel 14
Manufacturer Identification (MI) 15
Versions of the Manufacturer Identification 16
Versions of the Print Free Area 17
The Back Panel and Longitudinal Seam 18
Misalignment along the Longitudinal Seam 19
Re-Setting Dimensions 20
The Opening Devices
Punching and Applying the Straw 22
combiSwift 23
combiSmart 24
Cross-Section of the Opening Devices 25
Unprinted Areas with Opening Devices 28
Standard Print-Free Area (EDF) 29
Opening Instruction Pictograms 30
Designing
Colour Sequence/Printing Sequence 31
Colour Sequence Priorities 32
Colour Sequence 33
Colouring of Marks with Metallic Colour 34
Black Sequence 35
Colour Drift 36
First Tone Printed 38
Gradations 39
Overprinting 40
Spreading 41
EAN-Code Standard/UPC-Code 43
EAN-Code Free Zones 44
Special EAN-Code for ALDI 45
QR-Code 46
Standard Values 47
How to Save Money 48
Flooding – Test Proof 49
Control Marks 50
Special Engravings 51
Delivering Data
Information for Delivering Data 52
Check-List for Delivering Data 53
01
Doc.-No.: I-G-0146-en We reserve the right to Artwork Manual
Edition: V4 Appendix A (English) make technical changes Contents
n
o
ti
c
u
d
Typo o
r
TypJouice nt
Juice I
The System for Success.
SIG Combibloc is the company leading the way in the global
packaging industry. We manufacture aseptic carton packaging for
food such as milk, juice, soups and sauces while developing and pro-
ducing the required filling machines.
We are driven by the motivation of achieving joint success with
our customers. We use our high-grade, high-performance and flexi-
ble system to guide the entire packaging process. One portion of this
process is preparing packaging design for production in rotogravure
printing.
We would like to use this manual to support you in laying out
the design of your carton packaging. Applying the criteria described
in this manual will provide a reliable foundation for optimum imple-
mentation of your design ideas in the SIG standard.
02
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Introduction
Introduction
Carton Structure - The Carton Combination of combibloc
Raw board
Middle polyethylene coating
e
Aluminium r
u
Inner polyethylene coating ct
u
r
Printing on outer polyethylene coating t
S
combibloc combifit n
o
t
r
a
C
Creasing and punching
Folding and sealing
Sleeve dispatch
The strong edges ensure that the
carton is always on good shape.
The longtidudinal seam offers
aseptic safety.
The preformed carton sleeves are produced in Rotogravure printing for stunning colours
the packaging material facilities at SIG Com- After coating, a high-grade rotogravure printing
bibloc and they are later aseptically filled on the technique that is especially suited to high runs of
filling machines on the customer‘s premises. sophisticated products with intensive colours is
The carton is given an inside and outside layer used to print on the carton.
of high-grade polyethylene (PE) including an
extremely thin layer of aluminium and another
inner layer of polyethylene.
03
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Introduction
Introduction
The Printing Technique - The SIG Process
The structure of a rotogravure printing
cylinder and how it is engraved
The rotogravure printing cylinder consists of a
steel core with a thin layer of copper for the
engraving. The cylinder is chrome-plated after
engraving.
e
the digital data u
q
of the design ni
h
c
e
The engraving stylus T
with a diamond head g
n
engraves a mirror-im- ti
age of the design into n
the layer of copper. ri
P
e
h
T
the layer of
chrome after
engraving the detail of
engraved cells
A schematic diagram of the printing machine
SIG laminate drying unit
material
rewinder
M C Y Blue Black
printing direction
M C Y Blau Schwarz
A schematic diagram of the printing unit The rotogravure printing technique
Rotogravure printing is a direct printing
technique where all of the printing elements
are engraved to the cylinder surface as little
cells. The cylinder rotates in a trough filled
with low-viscosity ink. The ink flows into the
impression cell, while the surplus ink is scraped off from
cylinder
the print free zones with a doctor blade.
The ink is then transferred to the laminate.
SIG laminate material
direction of
printing
blade
printing cylinder
ink tray
04
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Introduction
Introduction
The Filling Process in the combibloc Filling Machine
product
s
s
e
sterile c
o
air Pr
H O g
2 2 n
magazine e Filli
h
T
1
2
3 6C
9
6A 6B 7 8
3 5
4
Magazine Aseptic area
1 6
The magazine holds the sleeves, and is refilled The aseptic area consists of the areas: sterilisa-
by the operator or the optional CAM module. tion (A), drying (B) and filling (C) of the carton.
First, hydrogen peroxide (H O ) is used to
2 2
sterilise the inside of the carton. Afterwards, the
heated sterile air is blown in at several stations
A
and thus dries out, the H O still inside. The
2 2
Sleeve extraction + opening-up of sleeves process is used to kill the micro-organisms
2
inside the package in a reliable way. The
The individual sleeves are extracted through product is filled into the carton in the filling
suction units, they are opened up rectangulary station at two stages. The aseptic area is under
and are pushed onto a mandrel. This ensures a slight overpressure of sterile air, thus avoiding
a reliable guidance for the production of the B the ingression of non-sterile air from the outside
bottom section. and thus preventing the aseptic area from being
contaminated.
Bottom activation
3
Hot air is used at two stations to activate the
areas of the bottom section of the sleeve.
C
Top sealing through ultrasonic sealing
7
Bottom folding The top section of the carton is folded by the
4
ultrasonic sealing tools and is sealed on top
During the time the mandrel wheel transports
of the fill level. Before sealing the carton with
the sleeve to the bottom pressing station, rotat-
ultrasonic energy, steam is injected into the
ing lateral folders and a longtidudinal folder are
carton to reduce the head space to a minimum
used to prefold the bottom section.
after the cooling-down process. A nitrogene
injection is available as an option.
Top forming station
Bottom pressing station 8
5
The polyethylene is heated up with hot air at
Bottom press dies and the face side of the man-
the top triangles and at the narrow side of the
drel are used to fully press and seal the bottom
carton, the top triangles are folded downwards
section of the carton. The specific design of the
and are sealed to the carton.
pressing elements ensures the typical, patented
concave-shaped bottom section guaranteeing
Ejector and discharge station
the particularly good standing features. 9
The carton is ejected out of the pocket, and is
put up and then placed onto the off-conveyor.
05
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Introduction
Introduction
The SIG Combibloc Workflow - Reproduction/Printing Management
preliminary phase /
graphic artists / customers
packaging design order placed with SIG
w
order placed (data, artwork, o
fl
Design Order Form Doc-Nr.: 10.F-SC 701) k
r
o
W
packaging is scheduled after
the packaging order is placed place reproduction order
and at the same time as and request proof
design implementation
internal correction loop
proof supplied
to SIG for checking
no
and sending to
customer
customer correction loop
customer reviews proofs
customer gives
approval for cylinder
no
engraving
Packaging Order
inquire Packaging Order
is placed no
cylinder produced and
test proof supplied to SIG
internal correction loop
SIG approves
production cylinder
no
packaging production
06
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Introduction
Working with the Keylines
The Structure of the combibloc and combifits Layouts (Back Panel Divided)
print free sealing area
top panel
back right
top panel
back left top front side
cylinder numbers
version no. of keyline
print free ear area
crease line crease line
lay-out area (background/picture)
back panel left left hand side panel front panel right hand side panel back panel right
type area marking type area marking s
t
u
e o
l y
connection mp connection La
spreading/bleed sa spreading/bleed bifit
m
o
c
d
n
printing number a
register marks print check register marks c
o
carton base bl
Interleaved Code bi
m
o
c
e
h
t
f
o
e
r
u
t
c
u
r
t
S
Format series e
h
T
cb4 · cb5 · cb6 · cb7 · cf7
longitudinal seam Area definition:
top back-
side left
print free sealing area Lay-out area
top front side
top backside
top back-
right
side left
Covered lay-out area,
with formed packaging
print free
ear area
Print free areas
right hand
side panel for ear area and opening device
front panel (white)
left hand
back panel
right bleafctk panel side panel Print free sealing areas
on top and bottom
m Type area marking
ea (dashed)
s
al
n
di
u
git Printable areas on the
on carton base (white)
l
an example of the cb format
07
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Keylines
Working with the Keylines
The Structure of the combibloc Layouts (Back Panel Not Divided)
print free sealing area
top panel back
top front side
cylinder numbers
version no. of keyline
print free ear area
crease line crease line
lay-out area (background/picture)
left hand side panel front panel right hand side panel back panel
s
t
u
o
y
connection connection La
c
spreading/bleed spreading/bleed o
bl
bi
type area marking type area marking m
o
c
e e
l h
p t
m f
o
a e
s r
u
t
c
u
r
t
S
printing number e
register marks print check register marks h
T
carton base
Interleaved Code
Format series
cb1 · cb2 · cb3 · cb8 · cb9
longitudinal seam
Area definition:
top back panel
print free sealing area
top front panel Lay-out area
top back panel
Covered lay-out area,
with formed packaging
print free ear area
right hand
side panel Print free areas
front panel
left hand for ear area and opening device
back panel side panel (white)
Print free sealing areas
on top and bottom
m
ea Type area marking
s
al (dashed)
n
di
u
git
on Printable areas on the
l
carton base (white)
an example of the cb format
08
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Keylines
Working with the Keylines
The Structure of the combifit Layouts (Back Panel Not Divided)
print free sealing area
top back panel
top front panel
cylinder numbers
version no. of keyline
print free ear area
crease line crease line
lay-out area (background/picture)
right hand side panel back panel left hand side panel front panel s
t
u
o
y
connection connection La
t
spreading/bleed spreading/bleed fi
bi
m
type area marking type area marking o
c
e
h
e t
l f
p o
m e
r
a u
s t
c
u
r
t
S
e
h
T
printing number
register marks print check register marks
carton base
Interleaved Code
Format series
cf2 · cf8 · cf9
top back panel
print free sealing area
Area definition:
top front panel
Lay-out area
Covered lay-out area,
with formed packaging
right
hand side Print free areas
panel for ear area and opening device
front panel
(white)
Print free sealing areas
on top and bottom
m
a
e
s
nal Type area marking
di
u (dashed)
git
n
o
l
Printable areas on the
carton base (white)
an example of the cf format
09
Doc.-No.: I-G-0146-en Artwork Manual
Edition: V4 Appendix A (English) Keylines