Ryerson University
School of Graphic Communications Management
GRA 534 – Printing Processes IV
Course Outline – Fall 2005
Instructor
Ian Baitz, Assistant Professor
email: ibaitz@ryerson.ca
Telephone: (416) 979-5000, extension 6199 (office)
Office is located in HEI 203, 125 Bond St.
An instructor web site is available at www.ryerson.ca/~ibaitz Some course documents, assignments,
exemplars, schedules and other useful resources are available from this web site.
Student Consultation (Office Hours)
As posted on instructor’s office door.
Other times are available by appointment.
E-mail
Students are invited to consult with the instructor by e-mail. Only e-mails from Ryerson Matrix
(ryerson.ca) accounts will be opened. E-mails from non-Ryerson accounts will be deleted unopened and
the sender will not receive a reply.
Prerequisites
(GRA 022 or GRA 422), (GRA 023 or GRA423) and (GRA 024 or GRA 424)
Corequisites
GRA 533
Course Description
The emphasis of this course is on web-offset printing, digital printing processes, flexography, and multicolour press capability analysis. In the lab component of the course processes and materials are tested at
an advanced level. Computer simulation of press systems is used to determine the economic benefits of
press room automation. Complex sheetfed and web-offset installations are critically analyzed for their technical
capabilities and cost effectiveness. New developments in printing press technology are discussed as they arise.
(Equivalent to first half of GRA 034). Topics shown in roman type are taught in GRA 534. Topics shown in italic
type will be taught in GRA 634.
GRA 534 – Printing Processes IV Course Outline
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Objective
To compare the advantages, disadvantages and limitations of the press production systems of the printing
processes. To select the most suitable process for a given product. To evaluate and predict the
performance of the materials used in the printed product with emphasis on full colour printing. To
understand the advantages and limitations of web and digital printing processes.
Standards
Standards of aesthetics, quality, measurement and value continue to be demanded this academic year. The
model is based upon industrial plants that have achieved excellence in quality and efficiency. All student
submissions will be presented in professional manner.
Teaching Methods
Lectures, research, readings, guest lectures, demonstrations, lab experiments. There is an online
component to this course using the Blackboard electronic learning environment. Some course content
will be presented using mixed mode delivery, face-to-face and online.
Lecture (1 hour), and
Lab (4.5 hours every three weeks)
Blackboard electronic learning environment
There is an online component to this course using the Blackboard electronic learning environment.
Students are advised to check the Blackboard course site twice weekly for any important announcements
or information.
Students are required to obtain and maintain a Ryerson Matrix (ryerson.ca) email account to access
Blackboard. Accounts may be activated online at www.ryerson.ca/accounts. It is essential that students
check their Ryerson Matrix email account regularly.
To log in to the Blackboard learning environment, visit http://my.ryerson.ca (No “www”). Technical
help with Blackboard is available from this site.
Texts
Web Offset Press Operating, Fifth Edition 2003, GATF Staff, GATF.
In addition the following texts used in GRA 014 and GRA 024 provide useful reference:
Color and Its Reproduction, Third Edition, 2004, Field, GATF.
Handbook of Graphic Arts Equations, First Edition 1999, Breede, GATF.
Sheetfed Offset Press Operating, Dejidas and Destree, GATF.
What the Printer Should Know about Ink, Second Edition 1995, Eldred and Scarlett, GATF.
What the Printer Should Know about Paper Third Edition 2000, Wilson, GATF.
Additional readings will be provided periodically from instructor handouts, online documents and library
holdings. Details will be provided of any additional required readings. A list of recommended readings
(available from the Ryerson Library) is available from the instructor web site www.ryerson.ca/~ibaitz
GRA 534 – Printing Processes IV Course Outline
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Library Reference
Understanding Color Management, Sharma, Thomson-Delmar.
Solving Sheetfed Offset Press Problems, GATF.
Solving Offset Ink Problems, GATF.
What the Printers Should Know About Ink, GATF.
What the Printers Should Know About Paper, GATF
Web Offset Press Problems, GATF.
Control Technologies for Web Offset, GATF.
Flexo Principles and Practices, FTA.
Journals
Graphic Communications Trade Journals - Library
Method of Evaluation
Students are evaluated by the following: projects and reports, attendance and exams. Details are provided
in this outline under “Assessments and Important Dates.”
Projects and Reports
Lab Attendance
Final Exam
55% of course mark
5% of course mark
40% of course mark
Students are expected to participate fully in all lectures and labs. In keeping with industry and academic
standards, all reports and assignments must be proofread. Marks will be deducted for numerous spelling or
grammatical errors.
Late Penalties
All work that is to be handed in is to be submitted in the GCM office or electronically, as outlined by the instructor,
prior to 15:00 on the due date. Work submitted late is subject to a penalty of 10% per day late (e.g. An
assignment evaluated at 85% but submitted two days late will be awarded a mark of 65%.) There is a
minimum penalty of 10% for work handed in after 15:00 on the due date. Weekends count as two days.
Assignments are considered submitted only when all required portions of the assignment are handed in. This
may include hard copies, disks, files, lab samples, printouts, press sheets, graphs, charts and supporting
materials. An incomplete assignment will be considered late until all required materials are submitted and
the standard late penalty will apply.
Students are required to maintain their own backup files for all projects. Lost, damaged or destroyed files will
not be accepted as a reason for non-submission or late submission of work.
Illness Affecting Completion of Assignments and Tests
In case of missed assignments, tests, exams or other marked work, students requesting consideration due
to illness will require the Ryerson University Student Medical Certificate. This is the only medical certificate that
will be accepted. Details, including a copy of the certificate itself, can be found in the GCM Survival Guide.
GRA 534 – Printing Processes IV Course Outline
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Religious Observances
Ryerson recognizes that a student’s religious observance may require an absence from a required course
activity. At the start of each term, students who have religious observance obligations which will lead to
absences from campus or academic activities during the semester should complete the Student Declaration
of Religious Observance form. The form should be presented to the Professor within the first two weeks of
class. A separate form is required for each class. Notification in advance is required.
If, upon release of the Examination Timetable, you find that you require an accommodation for a
religious observance, you should file another form, completing the section entitled “Accommodation for
the Final Exam” and submit it to the Instructor within 5 working days.
Detailed instructions and the Student Declaration of Religious Observance form are available from the
Registration and Records web site [www.ryerson.ca/rr].
Special Needs
Students with special needs or disabilities that require academic adaptations or services may, if they wish,
discuss their needs with the professor or contact the Access Centre
[http://www.ryerson.ca/accesscentre/].
The Writing Centre
Ryerson offers students free tutoring/assistance through the Writing Centre
[http://www.ryerson.ca/writing-centre/].
University Policy Resources
For policy guidance, students are advised to review the GCM Survival Guide and the current Ryerson
Full-Time Undergraduate Calendar. Information on academic consideration, appeals, religious holidays
affecting completion of student work and examinations is included in these publications. Academic
Policies may also be found at www.ryerson.ca/~acadpol/policies.html
Some particularly relevant policies and information are included below.
Grades
Under normal circumstances, the first mid-term grade will be available to students by the
end of the first full week of November.
Grades for tests and exams will normally be posted electronically on the course Blackboard web site
and/or on the GCM student bulletin board. All grades posted to the GCM student bulletin board are by
the last 7 digits of student number. Assignments will normally be returned to students in class or made
available for pickup at the GCM office. A notice will be posted electronically on the course Blackboard
web site and/or on the GCM student bulletin board to advise students when work is ready for pickup.
To maintain confidentiality, work will only be returned to the student(s) who submitted it.
Students who do not wish to have their grades posted must advise the instructor in writing. It is
requested this be done no later than the first two weeks of class.
Students are advised to specifically review the following sections in the current (2005-2006) Ryerson FullTime Undergraduate Calendar:
Student Code of Academic Conduct (pp. 67-81)
Graded Course Performance Designations through to end of Academic Standings (pp. 48-61)
Examinations (p. 46-47)
Graphic Communications Management Academic Standing Variations (p. 57)
GRA 534 – Printing Processes IV Course Outline
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Information on Academic Council Policy 134, Academic Consideration and Appeals may be found at
[http://www.ryerson.ca/~acadpol/policies.html]
Further information is contained in the current GCM Survival Guide.
Regrading and Recalculation
At any time during the semester, students who believe that an assignment, test or exam, either in whole
or part, has not been appropriately graded must first review their concerns with their instructor within
ten (10) working days of the date when the graded work is returned to the class. Grades not questioned
within this period will not be reassessed at a later date.
An instructor may require a written request for regrading, stating why the work warrants a higher grade.
It is not acceptable for students to request a higher grade without justification based on the merit of the
work. Note that regrading may result in a new grade which is the same, lower or higher.
Regrading or recalculation requests are not grounds for an appeal, but are matters for discussion between
the student and the instructor. Details may be found in Academic Council Policy 134, Academic
Consideration and Appeals at [http://www.ryerson.ca/~acadpol/policies.html].
Plagiarism
Plagiarism – in the broadest sense is misrepresenting the work of others as one’s own. Plagiarism
specifically can be understood as: the act of copying, reproducing or paraphrasing significant portions of
someone else’s published or unpublished material, and representing someone else’s thinking as one’s own
thinking by not acknowledging the appropriate source or failure to use the appropriate quotation marks.
In addition, it is inappropriate to represent as one’s individual writing and/or final product a jointly
written or produced submission of any description. Any co-authored submission must be clearly
identified as such. Students have the responsibility to learn and use conventions of documentation, and, if
in any doubt, are encouraged to consult with the instructor of the course, or the department
chair/director for clarification. For a full explanation of your rights and responsibilities, please refer to
the Student Code of Academic Conduct and the Student Code of Non-Academic Conduct on pages 67
to 87 in the current Ryerson Calendar.
Note also that academic misconduct includes submitting the same course work, research, or assignment
for credit on more than one occasion in two or more courses without the prior written permission of the
instructors in all the courses involved.
Turnitin.com
Students agree that by taking this course all required papers may be subject to submission for textual
similarity review to Turnitin.com for the detection of plagiarism. All submitted papers will be included as
source documents in the Turnitin.com reference database solely for the purpose of detecting plagiarism
of such papers. Use of the Turnitin.com service is subject to the terms of use agreement posted on the
www.turnitin.com site.
Students who do not want their work submitted to this plagiarism detection service must, by the end of
the second week of class, consult with the instructor to make alternate arrangements. When the instructor
has reason to suspect that an individual piece of work has been plagiarized, the instructor shall be
permitted to submit that work to any plagiarism detection service.
GRA 534 – Printing Processes IV Course Outline
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Core Course Rule
A failed grade in any of GRA 102, GRA 103, GRA 104, GRA 202, GRA 203, GRA 204, GRA 322, GRA
323, GRA 324, GRA 422, GRA 423, GRA 424 will result in a PROBATIONARY standing.
Enrollment in GRA 322/422, GRA 323/423, GRA 324/424 requires successful completion in each
of: GRA 102/202, GRA 103/203, GRA 104/204.
Enrollment in GRA 533/633, GRA 534/634 requires successful completion in each of: GRA
322/422, GRA 323/423, GRA 324/424.
Enrollment in GRA 741/841, GRA 743/843, GRA 704/804 requires successful completion in each
of: GRA 533/633, GRA 534/634.
Each core course at each level of the program is a co-requisite to the rest of the core courses at that level.
Students are responsible for ensuring that prerequisites for each course are clearly understood. Failure to
attain a prerequisite course will preclude advancement to the next level of the program and the student
will be required to repeat ALL core courses for that level. See also pages 20-21 of the current GCM
Survival Guide.
GCM Exam Rule
“The School of Graphic Communications Management has approved a policy by which students MUST
receive a passing grade (a D- or 50%) on the final examination in order to receive a passing grade.
Students who do not pass the final examination will NOT receive a passing grade in the course,
regardless of their marks on projects, assignments, other tests or other assessment items.”
The GCM Exam Rule applies in this course. For a list of all courses in which the GCM Exam Rule
applies, consult pages 16-17 of the current GCM Survival Guide.
Course Repeat Rule
Students should note that Ryerson policy (effective Fall 2002) states that no course may be repeated more
than twice. If the course is not successfully completed on the third try, the student is automatically
withdrawn from the program by the University.
Examination Policy
The Examination Policy (Academic Council Policy #135) is available in its entirety at
www.ryerson.ca/~acadpol/policies.html Relevant excerpts are included in the GCM Survival Guide.
The following devices may not be turned on or in the possession of students at their seats during a quiz,
test or exam: cellular phones, pagers, headphones/earphones, personal digital assistants (PDAs),
computers, and electronic entertainment or music devices. Calculators are permitted. Bags, coats and hats
must be placed at the edges of the room. Students are responsible for the security of their own
belongings. It is recommended students do not bring items of value into quizzes, tests or exams.
Instructor Evaluation
The Faculty Course Survey will be administered near the end of the term, at a date to be announced.
GRA 534 – Printing Processes IV Course Outline
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GRA 534 – Printing Processes IV
Assessments and Important Dates Fall 2005
% of
Grade
Indiv/
Group
Special Project
Proposal
10%
Plate Scanner Payback
Analysis
Assessment
Details
(Due) Date
G
Submit a proposal for a third-year
special research project.
Tue 11 Oct 2005
10%
I
Submit the report on the plate scanner
payback analysis completed using SHOTS.
Mon 31 Oct 2005
Flexsys Flexography
Simulator Exercises
10%
I
Submit the assigned exercises and
log files.
Mon 14 Nov 2005
Fall Term
Instrumentation Report
25%
G
Submit the report on the three instrumentation
tests required for this term. (Inkometer,
Tensile Strength and Prufbau Gamut
Comparision Tests)
Mon 28 Nov 2005
Fall Term
Lab Attendance
5%
I
Mark for Fall Term Lab Attendance
See Note 2 below
6 Sep – 2 Dec 2005
Fall Term Exam
40%
I
Lectures, labs, assigned readings,
notes and class discussions.
Exam Period
Total
100%
FALL TERM:
Notes:
1.
Alterations to due dates will be discussed with the class and official notification will be
provided in writing.
Attendance Mark
2.
Your attendance will bear closely on your success in the course. You will be awarded a mark for
lab attendance each term using the following formula.
Perfect Attendance = 5/5
Deduction for each Absence = 2 marks
Deduction for each Late = 1 mark
Minimum attendance mark = 0/5
Attendance will be taken at the start of each lab period. Students arriving late are responsible for
advising the instructor at the time of their arrival.
GRA 534 – Printing Processes IV Course Outline
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GRA 534 – Printing Processes IV
Summary of Topics
Note: Time indicated for each topic is approximate. Some topics will be instructed though the course Blackboard web site
in addition to or in place of classroom instruction. Topics are listed in approximate sequence of instruction, although changes
or variation may occur.
Topic 1
Introduction to the Course (1 hour)
Objective
To provide the course outline, marking scheme and due dates. To introduce the
course Blackboard web site. To identify expected participation and conduct.
Topic 2
Flexography Overview (1 hour)
Objective
To discuss flexography’s relative position in the marketplace. To identify typical
products produced in flexographic printing.
Topic 3
Types of Flexographic Presses (1 hour)
Objective
To identify the advantages, limitations and applications of central impression (CI),
in-line (IL), stack, and corrugated presses.
Topic 4
Anilox Rolls and Ink Metering Systems (1 hour)
Objective
To discuss the purpose, manufacturing and surface characteristics of anilox rolls.
To identify the three common ink metering systems their relative advantages and
limitations.
Topic 5
Flexographic Press Set-Up and Production Issues (1 hour)
Objective
To discuss the functionality of the vital mechanical flexographic press components,
with emphasis on print station mechanics and ink delivery & metering systems.
Topic 6
Flexographic Inks (1 hour)
Objective
To discuss the chemistry of water, solvent and UV inks and the methods by which
they dry. To list the factors that have an effect on the preparation of ink. To discuss
the effects that ink drying has on in-line processes. To emphasize the importance of
efficient clean-up and proper storage of inks. To evaluate the cost factors that are
associated with ink.
GRA 534 – Printing Processes IV Course Outline
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Topic 7
Packaging Substrates (1 hour)
Objective
A survey of substrates commonly used for packaging in general and flexographic
printing in particular, including paper and paper board, corrugated boards, laminates,
foils, and films.
Topic 8
Customizing Tone Reproduction (Online delivery - Blackboard)
Objective
To investigate the press, paper and ink factors that have an effect on tonal gradation
in black and white halftone reproduction. To demonstrate the use of conventional and
computer graphical analysis in order to show tone reproduction differences. To
explain methods for tone reproduction standardization with regard to various printing
conditions.
Topic 9
Tone Reproduction and Gray Balance for Four-Colour Process Reproduction
(Online delivery - Blackboard)
Objective
To apply the principles of tone reproduction to process colour reproduction. To
demonstrate the limitations of process inks. To investigate the causes of additive failure
and how to compensate for this phenomenon with correct black printer determination.
To explain the rationale for gray balance and to determine gray balance based on
existing printing conditions. To demonstrate various conventional and computer
generated graphs in order to plot optimal gray balance values.
Topic 10
Roll Handling and Warehousing (1 hour)
Objective
To appraise the available roll handling equipment from roll clamp trucks to automated
guided vehicles. To survey roll inspection procedures and inventory controls including
conventional and computerized systems.
Topic 11
Web Press Configurations (1 hour)
Objective
To survey the three major web offset configurations, in-line, blanket-to-blanket and
common impression (satellite) presses. To evaluate the technical capabilities of these
press configurations.
Topic 12
Web Offset Blanket-to-Blanket Printing Units (1 hour)
Objective
To explain cylinder pressure and timing. To identify the arithmetic of packing in relation
to the undercut and thickness of paper to be printed.
GRA 534 – Printing Processes IV Course Outline
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Topic 13
Web Offset Infeed and Splicing (2 hours)
Objective
To explain infeed, splicing and tension control in web presses. To evaluate roll
requirements.
Topic 14
Web Offset Tension Control (1 hour)
Objective
To explain the importance of tension control in web presses. To identify the quality and
production problems associated with tension variation. To learn the tension control
variables.
GRA 534 – Printing Processes IV Course Outline
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