MEET OUR SYSTEM FOR AUTOMATIC IMPOSITION AUTO IMP

BASIC INFORMATION

AutoIMP is a system that, based on the interaction of several solutions, is to lead to full automation of the generation, analysis and approval of sheets for printing.

The main goal is to generate such imposition systems that will be the most profitable from the point of view of the customer’s production system at a given time. In cooperation with the production system, it is to ensure that all ordered works are delivered for printing in due time, so that they can be finished and returned to the customer on time.

AutoIMP is software that automatically creates impositions for printing based on:

AutoIMP is written in C # .NET technology (Windows server required) and requires the following software installed on this server:

The principle of operation of AutoIMP:

  1. The client’s IT system informs AutoIMP about the orders to be printed through a structured form of XML. Each order will have full information on how to execute it:
    • product type
    • net format, gross
    • information about bleeds
    • binding method
    • the way of folding
    • refinements (foiling (type), spot varnishing, hot-stamping, etc.)
    • Access paths to PDF files with work and finishing
    • order number
    • deadline for printing
    • selling price
  2. AutoIMP sends to callas pdfToolbox server all delivered files for their proper preparation for printing – file standardization.
  3. AutoIMP allows you to manipulate PDF files in the process of:
    • preparing files for printing – preflight, adding barcodes to products for their subsequent identification in the production process – preprocessing
    • preparing files in a comprehensible and correct manner from the point of view of imposition software – IMP Flow – processing
    • final preparation of the resulting sheets for printing (adding specific markings on the sheets in specific places, calculating sheets with ICC profiles that save ink, generation of sheets with markings – QR-codes for product identification in the production process, etc.) – postprocessing.
  4. AutoIMP segregates files and properly sends them to IMP Flow, which performs impositions, e.g .:
    • by collecting similar inputs of work,
    • rules of conduct due to a specific type of product (e.g. business cards, posters, brochures, folders, notebooks, other products)
    • specific schedule of proceedings
  5. AutoIMP analyzes the generated sheets in terms of:
    • sheet occupancy (% coverage)
    • the number of repetitions of orders on the sheet
    • the total cost of production in relation to the sale price on this order book
    • production surplus (e.g. 5,000 pcs, printed 5,500 pcs)
    • reference whether the generated sheet will be possible to produce on a specific machine (e.g. sheet production time greater than the machine availability time on a specific day, summing up the preparation and printing times of subsequent generated sheets and relating them to the machine’s use time
    • use of different acceptance algorithms depending on the time of day, working days and weekends.
  6. AutoIMP informs the customer’s IT system about the location of a specific job, on which sheet, on which machine the work is to be performed and how much it will cost to produce it (in terms of costs defined and calculated by IMP Flow, i.e. the cost of paper, print preparation and the printing itself, the cost of folding and collecting premiums
  7. AutoIMP generates the following components:
    • production information in the form of an XML file (circulation, machine, paper, etc.)
    • JPG files with sheet preview
    • PDF files with imposition
    • Cutting JDF file – information for the guillotine
    • imposition report generated by Insoft IMP according to a specific template
  8. AutoIMP is adapted to update the status of work implementation, if the sheet generated by AutoIMP is accepted by it, but is rejected by the Customer’s employee – there is an API to transfer such information.
  9. AutoIMP allows you to generate sheets divided into sectors that will be subject to separate processes, e.g. the half of B1 sheet – B2 will be foiled with Softskin foil, while part of this foil in SRA3 format will participate in the process of digitally applying UV-3d varnish.
  10. Each sheet generated by AutoIMP has its own status – Ready, Accepted. This allows the operator to validate every ideal sheet recognized by AutoIMP. It is especially important in the first production implementation process. Acceptance of sheets can be automatic.
  11. AutoIMP has its own graphic interface – AutoIMPWeb – which enables:
    • searching and checking the parameters of the uploaded order
    • preview of each generated sheet
    • approval or rejection of the generated sheet
    • sending the sheet for manual modification by the operator
    • sending the works arranged on the sheet for manual imposition by the operator.
  1. We send the works for calculations every 15 minutes.
  2. There are two W hours in which all jobs are accepted due to the upcoming shipment date:
    • W1: 14.30 – deadline until today
    • W2: 20.00 – deadline until tomorrow, except work on 130g, Highgloss or Dripoff
  3. Pts. 1 and 2 refer to the working week – Monday – Friday
  4. On Friday, W2 hours: 20.00 – deadline for Monday
  1. We send the works for calculations every 15 minutes.
  2. The time needed to produce each sheet generated by IMP Flow is checked each time. If there are products on the sheet, the production (printing) time of which would be within 2 hours from the time of the first scheduled post-press activity and the sheet would not be accepted due to the accepted assumptions of accepting the ideal sheet, then such product is assigned a higher priority and it goes back to the basket. On the next call (in 15 minutes), the product is sent to IMP Flow with higher priority.


    The generated sheet with a product with a higher priority:

  3. it is placed first and the remaining products from the basket are selected to it;
  4. a sheet with such a product is accepted.

offset machines – Off-n

digital machines – Dig-n

foil and varnish machine – Autobond

machine for applying UV3D varnish, gold foil, silver foil – MGI

business card cutting device – Aerocut

  1. Presentation Folders – arranged according to defined dies. Printing of folders with offsets Off-2, Off-4 or Dig-1. We do not allow duplication on one sheet (unless it’s W hour).
  2. Business cards 85×55 and 90×50 with UV3D + Silver or Gold finish – placed under Aerocut + MGI, printing on any machine
  3. Business cards divided into formats and released separately, combined with one-sided and two-sided products. Print only on Dig-1 with the same orientation direction.
  4. If the product has UV3D and has a print run of more than 500 copies – Autobond
  5. If the product is a business cards or any product smaller than A4, then we combine one and two-sided (of course sorted by paper and finishes)
  6. If the product has a B1 format (680×980 mm) then: the bleeds should be 1.5 mm
  7. If the product has the B2 format (480×680 mm) is a one-sided poster, then: a sheet layout that allows printing on a Dig-1 or Dig-2 machine, which have differently defined margins parameters due to the horizontal / vertical paper feeding direction
  8. If the product has the B2 format (680×480 mm) then: the bleeds should be 0.75 mm
  9. Saddle-stitched catalogs <500 pcs. – printing of inner pages and covers on Dig-1.
    Collecting on the printer. One signature on one sheet – duplicated as many times as will fit.
  10. PUR glued catalogs for a total print run of 3000 pcs – printing of means and covers on Dig-1. Collecting inner pages on the printer. Printing with diagrams – spines of individual pieces touching each other – one cut (IMP standards with no dimensions). [If the quantity <500 pcs – then we set the CutAndStack and set „F2-1, F2-1, …” and send it to DigitalBoundPUR, if the quantity> = 500 pcs – then we read the Assembly Method and set it to OffsetBoundPUR.
  11. PUR glued catalogs over 3000 sheets – layout not combined with other products – printing – offset machines.
  12. Product covers PUR-glued catalogs for an ordered amount of up to 500 pcs that are not refined by MGI (colored foils, UV3D varnish) and Autobond (Selective Varnish) and do not have SoftSkin foil which fits in the 310×440 mm format are printed on Dig-4.
  13. Dig-4 (if it fits) works with no refinements, with glossy and matt foil.
  14. We divide the rest into
  • 1 or 2 sided,
  • with varnishes printed on an offset machine (DripOff, Highgloss, SoftTouch)
  • with 1 or 2-sided varnishes (UV varnish, UV-3d varnish)
  • golding, silvering
  • papers, weights
  • foils (matte, glossy, softskin)
  1. If the products contain Silver or Gold they always go to MGI.
  2. If they contain UV3D – they go to MGI.
    If their circulation is greater than 500 – they go to Autobond (If the component has Uv3d and NO Silver and NO Gold and is in circulation> = 500, it goes to the Autobond group <other parameters>. UNLESS it is specialHour – in this case they go on a Uv3d flow that only uses MGI machines.
  3. If they contain Selective Varnish – UV – they go for Autobond
  4. Preprint / offset papers printed on machines:
  • Off-2, Off-4, Off-6, Off-7
  • Dig-2, Dig-3
  1. If they contain Dripoff, HighGloss, Softtouch – printing on the Off-2 machine
  2. In other cases – printing on machines:
  • Off-1, Off-2, Off-3, Off-4, Off-5, Off-6, Off-7
  • Dig-1, Dig-2, Dig-3, Dig-4

Ideal sheet definition:

  1. sheet usage> 70%
  2. If there is Dripoff or Highgloss finishing – we do not allow repetitions on the sheet
  3. we generally do not allow repetitions
  4. You can repeat a given product on the sheet if:

+ its circulation> 10,000 and

+ the sheet on which it occurs is printed with an circulation of at least 5000

  1. For circulation above 5,000, overproduction is allowed with the coefficient „1.10” (e.g. a printed sheet with a print run of 5,000 would be accepted, which would include a product with an ordered print run of 14,500 pcs and would appear on it 3 times)
  2. For round runs of ordered products from the pool of: 500, 1000, 2000, 2500, 5000, 10,000, if they are on a sheet with a print run of less than 5000 – repetitions are not allowed
  3. Repetitions are not allowed for the Posters group
  4. For other print runs outside the pool of point 6 (non-round issues) – 2 repetitions are allowed (for example – it is allowed to repeat a leaflet on a sheet with a print run of 3000 on a printed sheet with a print run of 1500)
  5. Business cards 85×55 and 90×50 with UV3D + Silver or Gold finish – placed under Aerocut + MGI (3 columns 7 rows or 3 columns, 8 rows), approved if 3 different on one 3-column sheet
  6. Wastage ((quantity produced – quantity ordered) x product area) accepted – up to 1,000 sheets <15%, If above 1,000 – 10,000 <10%, above 10,000 <5%
  7. 12. MGI –
  • wastage <15%,
  • one repetition acceptable,
  1. Presentation Folders – we do not allow repetitions.

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