Flexographic printing is both efficient and economical. However, it demands attention to certain issues that can be overlooked in other printing platforms. 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 Kopco Graphics, Inc. to work as partners. The end result will be high quality labels and high customer satisfaction at a very economical price.

Notes to the Graphic Designer

All brands of graphic design software are geared to the offset printing process. Offset tolerances are tighter and also allowing 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.

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 plate areas, roll to roll (web) printing method and spongy self adhesive paper constructions define these tolerance limits.

Electronic Art Requirements

Platform
Our preferred platform is the Apple Macintosh. We have the ability to accept files in the following formats:
Software
*Adobe Illustrator v. CS3
*Adobe Photoshop v. CS3 (TIFF or EPS)
*Indesign v. CS3
*QuarkXpress v. 7

Send any graphics used in the file separately, do not embed graphics in the file, keep as a separate link. Please send a hardcopy or PDF of your art for comparison.

Compressing

For Macintosh use Stuff-it or "Create Archive" in OSX and for Windows use WinZip or Zip It.

Digital Media
*CD-ROM
*3.5” diskette
*Jaz or Zip disk
*e-mail attachment
*Kopco’s FTP site (contact your Rep for login information)
Label all disks with your company's name and contents. When files are placed on a disk, check that all links have been maintained and that all linked files have been copied to the disk. Make all compressed files self-extracting.

Fonts

Send all fonts used in your artwork. With postscript fonts be sure to indicate both screen and printer fonts. Remember to include fonts used in graphic files placed in your art. If you are unable to send us fonts, convert type to paths or outlines before sending us your art. Please note that no copy changes can be made to outlined text.

On small type sizes (4 to 8 pt) use boldface, san serif fonts. Make sure "TM" and "®" marks are large and bold enough to reproduce in a readable manner. Avoid using small white text, or drop outs, over process backgrounds. Pay attention to symbols embedded in placed graphics that have been reduced. Make sure type styles have been applied properly. For example, never apply bold or italic to a font, choose the version directly from the font menu only. Align columns and text using tabs, not the spacebar.

Colors

All colors need to be properly defined as CMYK process or spot (not RGB). All unused colors need to be deleted from the color palette (this includes placed EPS files created in Illustrator and Freehand). Spot colors need to carry their proper PMS designation - colors need to be named to reflect the colors that they will print.

When a color is opaque enough to overprint a background color, do not drop out the background. When in doubt about color opacities, please consult Kopco Graphics, Inc. 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 Kopco Graphics, Inc. to do necessary adjustments. Spot color should be from Pantone (PMS) approved charts.

Trapping

Leave all trapping to be done by Kopco Graphics, Inc. Flexographic Printing requires larger spreads than Offset. line to line registration of colors are not possible to hold on press.

Bleeds

Maintain 1/16" to 1/8” margins from dieline to art, unless it is an intentional bleed.

Extend bleeds 1/8” beyond the die cut edge of the label. Bleeds are not possible on items that are "butt cut".

Graphic Elements

Do not use hairline or smaller rules/lines. All lines should be .5 point minimum. If original art is to be downsized be sure rules are large enough to be at least .5 point after reduction.
Images should be cropped, scaled, and rotated in native application prior to placement.

Examples:

A 1 inch section of a 4” x 6” placed photo should never be used, only include enough of the unused portion for a bleed (1/8"). This speeds up proofing, image setting, and avoids postscript errors.

Images that are 300 dpi enlarged in another application 200% reduces the dpi to 150, which is unacceptable.

Do not use RGB files, convert files to CMYK before sending. Make sure all files sent to use are high resolution, 300 dpi minimum, 600 + dpi preferred for sharpest image.

Screens

Screens may range from 100% to a minimum of 3%. Any screens below 3% may not reproduce correctly nor look as you planned on the final printed piece.

Be very careful with gradient screens. Too many screens side-by-side and overlapping each other may not only look awkward, but can create undesirable colors, and can lead to postscript errors that delay image setting and make the art unusable. Please note that screens that fade to nothing - in any color - will show a hard line where the dots end. For example, a drop shadow over white will have a distinctive edge.

If at all possible, use gradient screens rather than blends.

Screen angles

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

Scans

All scans should be in “High Resolution Dot” processed in CMYK not RGB.

Miscellaneous

No "white out" please - all unwanted items need to be deleted, not covered with a white box. This includes flaws in scans and eps files, they should be cleaned up before being placed in artwork.
When sending one-color images for us to scan, we need clean black and white art, preferably oversized.
Does the customer have the rights to all copyrightable material?
Is this job a repeat or one we have done previously? Are there minor changes only?

Kopco Graphics, Inc. is not responsible for maintaining Food and Drug Administration guidelines. Please contact them for your particular needs.

Maintain 1/16" margins from dieline to art, unless it is an intentional bleed. Bleeds are not possible on items that are "butt cut".

Proofing

Kopco Graphics, Inc. provides the following proofs:

A Full color pdf proof sent to you by email for your review and approval.

A proof for color match must be output by Kopco Graphics, Inc. as a Watercolor Proof.

E-mail

We can accept files via email under 8 Megs in size.
Send to the person you wish by first name & last initial @kopcographics.com, all lowercase with no space. Be sure to include all attachments when sending e-mails.