Print Production Quality Control

If you're not checking these before sending your print to the factory… you're risking costly mistakes. 👇 From mismatched Pantones to visible repeat lines, even the smallest oversight can lead to expensive delays or flawed production runs. After 15+ years designing for brands like Paul Smith, Peter Pilotto and Lily & Lionel, I’ve developed a rock-solid checklist that ensures every print file I send is factory-ready, clean, and crystal clear. Here’s my go-to checklist I run through before sending any print file off to the factory — because getting your files factory-ready is one of the most important (and overlooked!) steps in a smooth, cost-effective sampling process. ✅ DPI Check – Always 300 DPI minimum. No one wants pixelated artwork. ✅ Scale Check – Print it out, hold it up to your body. Is it flattering? Too bold? Too small for that dress? ✅ Repeat Size – Does it fit within factory screens (32, 64, 81cm)? Is it appropriate for the garment size? Think maxi dress compared to a bikini. ✅ Seamless Repeat – Zoom in and scan your artwork from top to bottom. Any visible lines or flaws? Now’s your chance to catch them. Check the repeat lines horizontally and vertically. ✅ Print Technique – Is your file formatted correctly? (e.g. indexed for screen print, flat for digital, psd, Tiff?) ✅ Layer Organisation – Label your layers clearly or provide a flat file with unnecessary extras removed. You're factory will thank you for the clarity! ✅ Pantone Colours – Double-check that your colour references match your palette exactly. ✅ Tech Packs – This needs its own post (coming soon!) but make sure your print info is included clearly, i.e. scale, pantone references, printing technique etc. These steps help you avoid costly back-and-forth, save your client time and money — and keep your factory happy! What would you add to this list? Anything here you hadn’t thought of before? 👇 Want the full breakdown? I’ve just put together a free, detailed guide you can download or share with your team. You can get it here https://lnkd.in/eNJvTuEv #PrintDesign #FashionDesignTips #TextileDesigner #SamplingChecklist #FreelanceDesigner #SurfacePatternDesign #FashionProduction #DesignWorkflow

🎯 Ink Trapping in Offset Printing – The Silent Factor Behind Print Quality When we talk about print quality, terms like dot gain and gray balance usually come up first. But there’s another factor quietly shaping how your packaging looks: Ink Trapping. 🔹 What is Ink Trapping? It’s the ability of one ink to print and hold correctly on top of another already printed ink. 👉 Example: Cyan printed first, Magenta printed on top → creates Blue. The vibrancy of that Blue depends on how well Magenta traps over Cyan. 🔹 Why Does It Matter? ❌ Poor trapping → dull, muddy, inconsistent colors ✅ Good trapping → sharp, vibrant, brand-accurate colors 🔹 How Do We Check Trapping? By using trapping patches in control strips. Devices like X-Rite eXact provide numeric values—beyond just visual judgment. 🔹 Benefits of Monitoring Ink Trapping: Predictable color mixing (CM, MY, CY) Consistency across long runs Reduced rejections from “washed-out” prints Premium color accuracy for brand packaging ✨ Insight: Ink Trapping may look like a small technical detail, but in offset packaging printing, it’s often the line between average results and premium-quality print. #Printing #OffsetPrinting #Packaging #ColorManagement #Prepress #InkTrapping #QualityControl

The Unseen Hero of Print Quality: The Anilox Roll Audit Imagine a bustling printing press. Amidst the whirl of colors and the rhythmic dance of machines, there's an unassuming hero often overlooked: the anilox roll. Like a skilled artist silently toiling away, the anilox roll determines the vibrancy and clarity of each print, yet its maintenance often takes a backseat. This story isn't just about any component; it's about recognizing the crucial role of regular anilox roll audits in maintaining printing excellence. Improved Print Quality and Consistency Regular anilox roll audits are critical to ensuring top-notch print quality. According to a study by the Flexographic Technical Association, regular audits can lead to a 30% improvement in print clarity and consistency. These audits help identify issues like cell blockages and wear, which can significantly affect ink transfer and, consequently, print quality. Extended Anilox Roll Life Anilox rolls are significant investments. Data from the American Printers Association shows that regular audits and maintenance can extend the lifespan of anilox rolls by up to 40%. This extension is crucial in offsetting the initial investment costs, as it means fewer replacements and repairs over the roll's lifetime. Cost Efficiency in Ink Usage Inefficient ink transfer isn't just a quality issue; it's a cost concern. A report by the International Journal of Print Management highlighted that proper maintenance through regular audits can reduce ink waste by up to 25%. This reduction in waste directly translates into cost savings, making regular audits a financially savvy practice. Reduction in Downtime Downtime in the printing industry can be costly. The Print Services & Distribution Association (PSDA) notes that regular anilox roll audits can decrease machine downtime by as much as 15%. This reduction is due to the early identification and rectification of potential issues before they escalate into major problems, ensuring smoother and uninterrupted operations. Enhanced Operator Knowledge and Skills Regular audits do more than just maintain equipment; they educate operators. The Graphic Arts Technical Foundation (GATF) suggests that these audits enhance the understanding and skills of operators regarding anilox maintenance, leading to better overall print production management. The humble anilox roll, often unnoticed, plays a pivotal role in the printing process. Regular audits are not just a maintenance routine but a strategic investment in quality, efficiency, and cost-effectiveness. By understanding and appreciating the value of these audits, printing operations can witness a significant transformation in their output and operational health.

Standard Operating Procedure (SOP) for Garment/Textile Printing 1. Purpose To ensure consistent and high-quality printing on garments/fabrics by following a defined set of procedures that maintain product standards and minimize errors. a) Screen printing b) Sublimation printing c) Heat transfer printing d) Digital printing 3. Role & Responsibilities 3.1 Printing Operator :- Execute printing exactly as per approved sample and settings. 3.2 QC Inspector :- Verify alignment, color, and overall print quality throughout the run. 3.3 Production Manager :- Oversee the entire operation and ensure SOP adherence and compliance. 4. Materials & Equipment Required a) Printing machine (e.g., screen, sublimation, heat press, DTG) b) Approved print artwork/design (in digital format) c) Color standard (Pantone/Buyer reference) d) Printing inks or transfer materials e) Clean garments or fabric f) PPE (gloves, apron, mask) g) Cleaning and maintenance tools 5. Procedure 5.1 Pre-Production Preparation 1. Verify print approval sheet, artwork, and color references. 2. Ensure fabric/garment is flat, lint-free, and free of oil/stains. 3. Calibrate the printing machine based on material and print type. 4. Load correct ink or transfer media as per approved specification. 5. Confirm machine temperature, pressure, and alignment setup. 5.2 Test Printing 1. Run a test print on sample fabric. 2. Compare against buyer-approved reference (design, color, placement). 3. Obtain QC and production manager approval before starting bulk. 5.3 Bulk Production Printing 1. Load garment/fabric precisely into the printing station. 2. Monitor print alignment continuously. 3. Inspect every 10th piece during production. 4. Document batch number, operator, and time for traceability. 5.4 Post-Printing 1. Cure/dry the ink as per material specification (e.g., 160°C for 90 seconds). 2. Conduct QC checks for: a) Colorfastness (wash & rub resistance) b) Placement accuracy c) Print clarity (no bleeding or ghosting) 3. Tag and segregate defective garments. 4. Store printed garments in a flat, dust-free area. 6. Quality Control 6.1 100% visual inspection for every piece. 6.2 Acceptable tolerance for print placement: ±3mm. 6.3 Reject prints with: a) Misalignment b) Smudging or ghost image c) Color mismatch (>5% from Pantone reference) d) Ink cracks or poor curing Maintain daily inspection and rejection reports. 7. Safety Guidelines 7.1 Operators must wear gloves, aprons, and masks. 7.2 Ensure all ventilation systems are active during operation. 7.3 Keep chemical MSDS sheets accessible. Clean ink spills immediately to avoid slip hazards or contamination. 8. Documentation 8.1 Print Production Logbook (date, shift, style, quantity, operator) 8.2 Approved Sample Records 8.3 Defect/Rejection Reports 8.4 QC Audit Reports 8.5 Machine Maintenance Logs

“𝗪𝗵𝘆 𝗬𝗼𝘂𝗿 𝗣𝗿𝗶𝗻𝘁 𝗟𝗼𝗼𝗸𝘀 𝗚𝗿𝗲𝗮𝘁 𝗼𝗻 𝗣𝗿𝗲𝘀𝘀… 𝗯𝘂𝘁 𝗪𝗿𝗼𝗻𝗴 𝗶𝗻 𝘁𝗵𝗲 𝗦𝘁𝗼𝗿𝗲” 𝗬𝗼𝘂𝗿 𝗽𝗿𝗶𝗻𝘁 𝗹𝗼𝗼𝗸𝗲𝗱 𝗽𝗲𝗿𝗳𝗲𝗰𝘁 𝘂𝗻𝗱𝗲𝗿 𝘁𝗵𝗲 𝗽𝗿𝗲𝘀𝘀 𝗹𝗶𝗴𝗵𝘁. 𝗕𝘂𝘁 𝗶𝗻 𝘁𝗵𝗲 𝘀𝘁𝗼𝗿𝗲? 𝗡𝗼𝘁 𝘀𝗼 𝗺𝘂𝗰𝗵. Chances are, it’s not the ink. It’s the measurement mode. 𝗛𝗲𝗿𝗲’𝘀 𝘆𝗼𝘂𝗿 𝗰𝗵𝗲𝗮𝘁 𝘀𝗵𝗲𝗲𝘁: 🔹 𝗠𝟬 – Old-school, no UV control. Still floating around… often unknowingly. 🔹 𝗠𝟭 – D50 simulation. The new default. Closest to what your customer sees. 🔹 𝗠𝟮 – UV cut. Needed when OBAs get involved (think uncoated stock). 🔹 𝗠𝟯 – Polarized. Tames the gloss. Useful for foil, film, and textured jobs. Choosing the wrong mode throws off your data. And your brand color match. 𝗣𝗿𝗼 𝘁𝗶𝗽: Align your 𝗽𝗿𝗲𝘀𝘀𝗿𝗼𝗼𝗺, 𝗤𝗔, and 𝗯𝗿𝗮𝗻𝗱 𝗼𝘄𝗻𝗲𝗿 on mode usage early. Are your teams all measuring the same way? Or speaking different languages in LAB? 𝗟𝗲𝘁’𝘀 𝘁𝗮𝗹𝗸 #𝗖𝗼𝗹𝗼𝗿𝗖𝗼𝗻𝘁𝗿𝗼𝗹. #Spectrophotometry #BrandColor #AllThingsPrint #ExperienceMatters