INTRODUCTION

Accord Carton is a full service folding carton company. Our prepress is equipped with a CREO Trendsetter 5467 for plate production.

Our printing excellence and uniformity are directly a result of the prepress procedures and materials provided to us. The standardization of our printing process and the matching of prepress to our specifications is critical. Each of our prepress suppliers will receive a copy of these specifications.

If files are not submitted as outlined in the “Preferred File Format” section of this document, files will have to be processed through Accord Carton’s digital center. This may result in additional prepress charges.

In order to minimize the costs for our customers, Accord has taken the strategic approach to provide full service prepress through regional digital hubs. This allows for centralized file archiving, standardized file formats to simplify “catastrophe planning”.

We strongly recommend our graphics suppliers to involve our prepress staff in the graphic design process as early as possible. Accord prepress personnel can provide additional insight to the graphic designer for possible manufacturing savings and improved product consistency.

SPECIFICATIONS FOR SUPPLIED GRAPHICS FILES

File Preparation

Graphics Composition to Cutting Die

Graphics must be composed to Accord’s cutting die CAD drawing. This is required in order to ensure proper panel registration and bleeds for the graphics. CAD files will be sent by Accord upon request. The die file must come from Accord’s CAD system to ensure that the graphics will layout (I.e., step and repeat) properly.

Color-to-Color Overlap or Trap

Overlap should be 0.005 to 0.007 inch. Traps for metallic inks should be 0.003 inch due to their unique printing characteristics.

Image Bleeds

• Around Outside Edges of Carton: 1/8 inch past the knife cut.
• Glue Flaps .1875 inch over the score depending on individual carton style/design. Please contact Accord’s prepress personnel for carton specific recommendations.
• Dust Flaps: ¼ inch over the score.
• Glue Areas: Must be free of any ink or coating.

Reverse Type

• Font Selection: Small type eland fine serifs should not be used for reverse type.
• Minimum Size: 8 point.
• Minimum Thickness: 0.004 inch at the thinnest part of a character or rule.
• Knockout Size: Dominant color (usually 70% or more) will be a straight drop out. Other colors will be spread (a.k.a. “keep away”, “undercut”, “hold back”) 0.003 inch.

Universal Product Code (UPC) and Other Bar Codes:

• Size: 80-100% (100% is preferred)
• Truncation: Truncation is allowed only on 100%-size barcodes.
• Color: Must be printed in the darkest color. Reds and purples should not be used.
• Bar Width Reduction: 0.002 inch
• “Quiet Zones” measuring _ inch on both sides of the barcode are requited.
• Barcode Standard: Refer to ANSI document Bar Code Print Quality Guidelines X3.182 for additional technical specifications.

Register Marks

• Color-to-color register marks should be placed on internal flaps of the carton that are not visible when the carton is made up. Each carton should have at least two sets of marks position diagonally from each other.
• Register marks must print as part of the printed sheet, however, they may cut off the final product.
• Center Lines: Crosshairs or register targets should be centered at the top, bottom, left and right of the die, 1/8” inch outside the die cut line.

Process Control Targets

• Process control targets must be included for every color in the file and should be incorporated into the final product (e.g., on inside tuck flap of a carton).
• Type of control patches: Inclusion of these control targets is imperative. However, the position and order of the targets is at the discretion of the graphic designer.

1. Dot Gain Targets: 3/16-inch square tint blocks with a 50% screen and solid of each color. Also 3/16-inch square tint blocks with tone values of 5%, 25%, 50%, 75% and 95% for all process colors must be included within the file, but outside the image area. These will be used to verify the accuracy of data transfer and/or interpretation.
2. Process Trap Targets: 3/16-inch square blocks for measuring ink trap of process colors: green (100% yellow and 100% cyan), red (100% yellow and 100% magenta), and the blue (100% magenta and 100% cyan).

Color Separations

- Screen Ruling: 175 lines per inch unless otherwise specified.

- Dot Shape: Square dot

- Screen Angles: To be determined by the separator to minimize moiré or electronic pattern.

- Rich Blacks: Rich blacks should be built by using 100% Black, 60% Cyan, 40% Magenta and 0% Yellow.

• First Preferences: Gray Component Replacement Separations
• Gray Component Replacement (GCR): Prefer 60% to 80%. It is also important to add color back under blacks to maintain gloss and density.
• Total Area Coverage Removal (TAC): The total of dot percentages in any spot in the four-color file should be no more than 280%.
• Under Color Removal (UCR): Normal UCR.

Manufactured Colors: When mixing screen tints of process colors to “manufacture a special color, only one process color should be a solid.

Second Preference: Conventional Separations.

Total Area Coverage (TAC): The total of dots percentages in any spot in the four color file should be no more that 280%.

Under Color Removal (UCR): Maximum allowable UCR.

Manufactured Colors: When mixing screen tints of process colors to “manufacture” a special color, only one process color should be a solid.

File Submissions

Preferred File Format: Native

NOTE: To avoid additional prepress charges from Accord Carton Company, all graphics files must comply with the File Preparation specifications described above and be submitted as outlined in this section.

Format: Files should be submitted as Native files with all Hi-resolution images included along with all fonts. Due to the constant upgrading of computer hardware and software please contact one of Accord’s prepress personnel for current revision level if a newer version is desired.

Color Naming Convention for Separation Layers:

Process Colors: Name each process color layer, in print rotation order as follows: Black, Cyan, Magenta and Yellow.

Spot/Special Colors: Name each spot color “Ink Book” names. For example, “PANTONE Red 032 CVC”.

Die Layer: The layer with the cutting die line must be named “die” & set to overprint. The display color for the die can be any color that this easily visible and contrasts with the graphics and must also be named “die”.

Job Size: The final “job size” must be set to match the size of the die.

Ruler Position: The ruler must be set to be at the center of the “job size”. Trap or Color-to-Color Overlap: The file must be properly trapped following the Color-to-Color or Trap specification listed in the File Preparation section of this document.

Fonts: All fonts must be outlined (I.E., converted to paths).

Optional File Communication: Files may be e-mailed when small or posted to an FTP site when large. Contact you CSR when jobs have been emailed or FTP posted.

Linked Files: All linked files must be included with the final file.

Proofs: All of our customers must approve proofs for color, color break and copy, These proofs are to be signed and dated as OK to print. Proofs must also follow the specifications outlined in the Specifications for Supplied Digital Proofs sections of this document.

Alternative File Format Submissions

If it is not possible to provide graphics files as outlined in the Preferred File Format section of this document, Accord can receive other file formats as specified in this section. In general, regardless of format, the submitted file must be editable so that the output can be adjusted to match the printing characteristics of our printing process.

File Preparation: No matter which software is used, the specifications for File Preparation (see section above) should be followed. If the file preparation specifications are not followed, considerable amount of time will be required to convert the supplied file. This may cause additional prepress charges and may delay production.

Work Flows: The file converting process, or workflow, must be determined on a case-by-case basis. Workflows are established for separated Postscript files and for DCS files (eps sub files).

Prepress Charges: Prepress charges will depend on the amount of time required to convert the submitted file to Accord Carton’s specifications. Charges will also depend on the type and quantity of prepress proofs required. Quotes can be provided on a case-by-case basis through your Accord CSR.

Proofs: A signed digital proof showing copy and color break of the graphics must be supplied with the file. Proofs must also follow the specifications outlined in the Specifications for Supplied Digital Proofs section of this document. Black and white progressive proof of each color should also be provided with each file.

Software: Adobe Illustrator is preferred. However, most common Windows & Macintosh-based programs can also be supported (e.g., Illustrator, Freehand, Quark, PageMaker, etc.).

Preferred Storage Media: CD

Specifications for Supplied Digital Proofs

Type of Proof

Preferences: Digital Contract Proof from a Kodak Approval or Fuji final.

Base Material: Actual Paperboard material used for production.

Special Colors: Fifth and sixth colors may be made from overlay materials or special color laminates.

Any other type of proofing system must receive special approval form Accord prepress personnel.

Process Control Targets

Process control targets must be included on every digital proof. Inclusion of these control targets is imperative. However, the position and order of the targets is at the discretion of the graphic designer. All of press proofs must include a color bar. This color bar must be within the file but outside the live image area at 175-line screen on all halftone proofs -- analog or digital. The color bar must include:

Density Control Target 3/16- inch square solid blocks of each process color. Proof ink density values on dry proofs should fall within the ranges listed below. (NOTE: Density measurements are based on “Status T” densitometry using and X-Rite densitometer.)

Black 1.70+0.10
Cyan 1.35+0.10
Magenta 1.35+0.10
Yellow .90+0.10

Dot Gain or Tone Value Increase Targets: 3/16- inch square tint blocks with tone values of 5%, 25%, 50%, 75%, and 95% for all process colors. In order to ensure properly balanced tone reproduction it is recommended that Total Dot Gain at 50% from the file to print should be as listed below. It is preferable to run on the high side of the target value (within tolerance) rather than the low side to allow for an easier match by production presses. In order to help obtain proper gray balance, gain values of the three colors (Y,M,C) should not differ from each other by more than 4% from their target value. That is: If either cyan or magenta is + 2% (24%) in dot gain, yellow deviation should not be greater than -2% (18%). (NOTE: Dot Gain or Toner Value increase measured at 50% tone using an X-Rite densitometer.)

Black 22%-26%
Cyan 20%-24%
Magenta 20%-24%
Yellow 18%-22%

Ink Trap Targets: 3/16-inch square blocks for measuring ink trap of process colors: green (100% yellow an 100% cyan), red (100% yellow and 100% magenta), and blue (100% magenta and 100% cyan). Two-color overprints at 25%, 50% and 75% are also recommended.

Gray Balance Target: At least one 3/16-inch square gray balance control target (cyan=50%, magenta & yellow=39%).

Color Sequence/Rotation: Printing rotation for process colors will be from darkest to lightest: Black, cyan, magenta, yellow. Since special colors can be in front or in back of this sequence, please consult with Accord Carton’s prepress personnel to determine the desired rotation if trapping (color-to-color overlap) is involved with the graphics. NOTE: Off-press proofing materials often specify a particular color application sequence. This may not necessarily be the same as the production printing sequence.

IMPORTANT: ALL FILES AND PROOFS WILL BE REVIEWED FOR CONFORMANCE TO THESE SPECIFICATIONS. ACCORD RESERVES THE RIGHT TO REJECT ANY FILES OR PROOFS THAT DO NOT MEET THESE SPECIFICATIONS.