Commercial manufacturing,surface treatments and finishes

Question 1

What is a flyer?

Answer 1

Traditional a flyer was the cheapest way to promote or sell a product or service
it would be made from cheap ,low-grade ,often coloured paper with one colour printing.
simple to get the message through

Question 2

What is a leaflet?

Answer 2

higher grade paper suitable for full colour printing. More time would be spent to ensure the information being given was appropriately publicised and images are used to make it more eye catching

Question 3

What is the problem with using card for packaging?

Answer 3

very absorbent if it is left untreated
can be treated and processed to improve functionality and enable it to be waterproof and grease proof however these coatings can make the card harder to recycle and slower to biodegrade.

Question 4

Why are papers and bards better than plastics?

Answer 4

Plastic take a very long time to biodegrade whereas paper and boards products are fully biodegradable and recyclable

Question 5

CASE STUDY: tetra pak

Answer 5

One of the most popular card based food packaging methods is tetra pak .The company produced a layered card that can hold liquid and food products safetly .Until quite recently tetra pak products have been very difficult to recycle as the many different layers that they consist of were difficult to separate .

Question 6

What did tetra pak do to their card?

Answer 6

the company has been using bio-based materials to allow the used cartons to be recycled more easily reducing the amount going to landfill sites

Question 7

What are carton boards and waxed papers?

Answer 7

come as a flat net that is constricted in the food outlet as needed saving on storage space
the nets of the products are usually die cut outs and the inner lining and paper parts that come in contact with the food or liquid are specially coated to prevent absorbency

Question 8

What does a die consists of?

Answer 8

crease rule,sheet material,creasing channel, cutting blade ,cutting plate and ejection rubber

Question 9

How does the die process begin?

Answer 9

1) The blank sheet of material is printed on if required

2) the cutting die is set in the machine’s support data

Question 10

What is the 3 and 4 step of die cutting?

Answer 10

3) the sheet material is loaded and aligned into the cutting plate
4) pressure is applied to the cutting plate which makes contact with the die

Question 11

What are stages 5 and 6?

Answer 11

5) the sheet material is cut out

6) the cutting plate lowers to reveal the cut sheet material

Question 12

What is the last step for the die process?

Answer 12

7)the material is removed from the machine and the process repeats

Question 13

How are commercial colours made?

Answer 13

blending specific amount of base colours to form the required shade or tone
the printing process uses two main ways to form colors RGB and CMYK

Question 14

What is CMYK and RGB?

Answer 14

CMYK–cyan magenta yellow and key(meaning black|)

RGB–reg green and blue

Question 15

What is offset lithography?

Answer 15

mass produced printing and very long print runs tend to use offset lithography (offset printing)
an aluminium sheet is exposed to a laser image to create a page master and then this sheet is then attacked to the plate cylinders

Question 16

How is a image area created?

Answer 16

ink and water is applied via rollers to the plate cylinders

parts of the plate cylinders are kept wet but the water rollers so the ink does not stick to these areas

Question 17

How is the image mirrored?

Answer 17

the ink plate cylinder transfers the image to the to the rubber blanket cylinder(offset cylinder)
at this point the image is mirrored,finally it is transferred to the material.Process is repeated for each of the colours required.

Question 18

Why are registration marks used?

Answer 18

to ensure that all the different coloured inks are correctly aligned

Question 19

Why are crop marks used?

Answer 19

used to show the printer where to trim or guillotine the sheet.registartion marks are placed out side the cropped marks so that they be checked without interfering with the image

Question 20

Why are colour bars used\?

Answer 20

used to help the printer see whether the colours are true and of the correct intensity and whether any adjustments are needed

Question 21

Why is less moisture better?

Answer 21

size is used to control the absorbency of the paper.
less moisture the paper absorbs the better the print quality this is because ink dries on the surface rather that being taken into the paper itself.
results is a brighter more intense and defined image
Another benefit is that it allows liquids and food products to be contained

Question 22

What is paper often coated with?

Answer 22

clay chalk or other fine powdered based materials which increases its smoothness and reduces its absorbency.
sometimes polymers or waxes are used as coatings to make material waterproof

Question 23

When des internal sizing take place?

Answer 23

whilst the paper is in the pulp stage although additional surface sizing takes place as the paper is being finished the coating added at this stage can include starch, gelatine, wax and polymers-based layers

Question 24

What surface finished are applied to paper and boards

Answer 24

either a liquid or powered ink is applied or bonded to the surface of the paper.Many different quality paper are available in different thicknesses as well as wide selection of sheens from high gloss through levels of statin to matt

Question 25

What is the difference between embossing and debossing?

Answer 25

creates a raised profile or pattern on the surface of the paper whereas as debossing creates a recessed profile or pattern .

Question 26

What is the process of debossing/embossing?

Answer 26

2 plates being created known as teh relief die and the counter die.
Just as in folding or creasing paper and card the fibres are permanently compressed and stay in position .
the paper or card is then placed between the 2 dies and pressure and sometimes heat is applied to the two parts .The material is then removed and the raised or recessed pattern remains

Question 27

When is embossing used?

Answer 27

braille writing that can be found on many products specifically medicine packages and labels

Question 28

What is UV varnishing?

Answer 28

surface of the card to be printed with a shiny transparent varnish
gives a high quality finish to broches cards and documents
vanish is applied through stencil and is then exposed to uv light which cures the varnish instantly

Question 29

What is lamination?

Answer 29

application of polymer film to the surface of a product.This protects the printed document to ensure it last longer and is less prone to damage from grease and moisture

Question 30

What id the bad side to lamination

Answer 30

applied single or double side however it does not seal around the edges like encapsulation lamination
this leaves the edges vulnerable to absorption

Question 31

What is polymer laminate?

Answer 31

new processing technique also allows it to be applied as a liquid
laminate is often applied to the covers of paperback books and can be identified by the outer cover which is smooth and usually shiny whereas the inside cover is left unprotected

Question 32

What happens if you done treat the paper with a surface treatment?

Answer 32

can become moldy if allowed to become damp owing to poor storage.These materials can also make a good home to mice rats and other nesting creatures

Question 33

What is UV degradation?

Answer 33

UV light breaks down colour pigment in the materials and fading colours
colours can lose their depth relatively quickly and white materials tend to be yellow over time
material can also weaken and become more prone to ripping