report on a press

DEPARTMENT OF GOVERNMENT PRINTING

D.D.S.Sirikumara Individual Project

1 JO/16/ICT5/1/0022

Content

Topic Page

1). About Organization 2

Name

Organization type

Scale of the company

Description

2). Services and Products 3

3). Old Printers 6

4). Printing Technology 7

Offset Printing

Laser Printing

All in one printing

Digital Printing

5). Section of the printing Press 27

Pre-Press Section

C2P (Computer to Plate) Section

Computer to Paper Section

Plate to Paper Section

Finishing Section

6). Customer Handling and Target 32

7). Memories of field visit 33


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Name : Department of Government Printing

Organization type : Government

Scale of the company : Large Scale

Description about Department of Government Printing

Department of Government Printing is the official press and publisher for the

government of Sri Lanka. Since the publication of the very first Gazette in 1802,

the Department of Government Printing has been the official printer and publisher for the

government of Sri Lanka. Having witnessed social, political and technological changes of more

than two hundred years, today the department stands as one of the oldest governmental

organizations in the country.

It is equipped with both machinery and skilled staff to handle almost any kind of printing

requirement. Whether it’s printing Forms for governmental organizations; or doing security

critical print jobs such as printing Stamps or Ballot Papers.

Now it has also taken the next step towards the Information Age and started publishing its content online.

Vision :

"To become the nation's hallmark of excellence in Printing and Publishing"

Mission :

"To provide printing and publishing services with assured quality in time to delight customers

with the help of innovative technology and dedicated staff"


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Department of Government Printing, Services and Products…

The press provide following services and products for the customers,

Gazettes

School Pupil’s Books

Visiting Cards

Other type of Books

News Papers

Examination Papers

Stamps

Ballot Papers

Bills

Calendars

Acts

We can download its digital publications from the “Publications” section of its

web site.

Online ordering

https://www.facebook.com/dulithasandaruwan


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Gazettes

Gazette is a journal about, what parliament discussed about the country. Department of Government Printing Press print Gazette every Friday. They print thousands of copies very fast, using their Offset Printing Machines.

School Pupil’s Book

It print school pupil’s books for the government school for low cost. Department of Government Printing Press is doing a great service for Sri Lankan Educations.

Examination papers

Examination papers are very secret. So no one inside who print paper is not allowed to go outside within exam duration for any reasons. So it will ensure that exam is conduct well .if exam paper went outside before the exam dates, mostly printing press has to responsible for it.


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Stamps

…………………………………………………………………………………………………………………….......


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Old printers


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Printing Technologies

1). Offset Printing:

Offset printing is a commonly used printing technique in

which the inked image is transferred (or "offset") from a plate to a rubber blanket, then to

the printing surface. When used in

combination with the lithographic process,

which is based on the repulsion

of oil and water, the offset technique

employs a flat image carrier on which the

image to be printed obtains ink from ink

rollers, while the non-printing area attracts a

water-based film(called "fountain solution"),

keeping the non-printing areas ink-free.

A little history

Development of the offset press came in two versions: In 1875 by Robert Barclay

of England for printing on tin, and in 1904 by Ira Washington Rubel of the United States for

printing on paper.




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Before Offset Printing

Every printing process starts with the creative process. Writers, editors, graphic designers and

artists are the initial step in the creation of flyers, magazines, brochures, books and other

print pieces.

After the artwork has been completed, edited and proofread, a digital "printer's file" is ready

to print.

1st step: Pre-press

Before the job can be printed, the document must be converted to plates. The plates are

created from digital file. Each of the primary colours - black, cyan, magenta, and yellow - has

a separate plate.

We are using the best plate material, aluminium instead of paper plates, which are cheaper

but not so good quality.



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2nd step: Press Run

The pre-cut paper

is fed through the press. The image area of

the plate picks up ink from the ink rollers.

The water rollers keep the ink off of the

non-image areas of the plate. Each plate

then transfers its image to a rubber

blanket that in turn transfers the image to

the paper. The plate itself does not

actually touch the paper - thus the term

"offset" lithography. All of this occurs at

an extremely high speed.




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The Inking Process

Ink and water do not mix - this is the underlying principle of offset lithography. The

ink is distributed to the plates through a series of rollers. On the press, the plates are dampened,

first by water rollers, then ink rollers. The rollers distribute the ink from the ink fountain onto the

plates.





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3rd step: Finishing

When our presses have finished the printing process:

The papers are trimmed to the final size using our guillotines.

The cut papers can be

• left as they are for flyers, leaflets

• folded for folded leaflets

• Bound, stitched and laminated for books and booklets.





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https://www.google.lk/search?q=heidelberg+sordz+printing+machine&espv=2&biw=1600&bih=799&source=lnms&tbm=isch&sa=X&ved=0ahUKEwjpmLfmiZfPAhVIpI8KHfP8B2gQ_AUIBigB#tbm=isch&q=dulitha+sandaruwan&imgrc=wx9Hy0N0zYkLKM%3A







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Advantages of offset printing

High quantity runs

Offset printing is typically used for large print volumes with a minimum of 1,000 copies. If

you require large quantities, then offset printing is better option.

Cost-effectiveness in high volume

Offset printing is cost effective for high volume prints. It is budget-friendly when it comes to

large runs as the cost per unit goes down with the increase in the quantity of prints.

Superior image quality with vibrant colors

Offset printing produces consistent image quality with higher resolution. Also, the image

quality is sharp and clean with vibrant colors. You can print on a variety of surfaces including

plastic, cloth, wood and metal using offset printing.

The operator said it could print 20000-25000 copies per hour. Off-set printing

method very fast. So I think it’s very useful for Department of Government

Printing …

https://plus.google.com/u/0/113105002340275138273






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2). Laser Printing

Laser printing is an electronic digital printing process. It produce high quality

text and graphics (and moderate quality photographs) by repeatedly passing a laser beam

back and forth over a negatively charged cylindrical drum to define a differentially charged

image. The drum then selectively collects electrically charged powered ink (TONER), and

transfers the image paper, which is then heated in order to permanently fuse the text and or

imagery. As with digital photocopiers and multifunction /all in one inkjet printers, laser

printers employ a xerographic printer process. However laser printing differs from analog

photocopiers in that the image is produced by the direct scanning of the medium across the

printer’s photoreceptor. This enables laser printing to copy images more quickly than most

photocopiers.




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Laser printing processes

Cleaning

The cleaning phase cleans up the work from the previous page to prepare the

Drum for printing a new page.

Primary corona

The primary corona then Charges the Drum with a negative charge.




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Laser writing

Then the laser shouts a beam into the into a mirror. Then the mirror reflects it onto

photosensitive drum.

Developing

Toner is applied electrically to the areas on the Drum that were written by the Laser.

Transfer

The Transfer Corona wire applies a positive charge onto Paper that pulls the negative

charged Toner onto the Paper.

Fusing

Finally the fuser heats and the paper rolls into pressure rollers. Which melt the Toner

particles into the Paper.




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Government Printing Press use laser printing technology to print high quality color copies

using HEIDELBERG SPEEDMASTER printing machine. It is easy to use more than other machine

that they have in the company.








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3).All in one printing

Government Printing Press have one printing machine in their company. It could

complete a complete book with binding and printing the book.it only needs a template to

print the book. Workers said it is efficient for if we need less than 250 copies of the book.it

will take more cost if we use offset printing, because if needs to create plate for every page

of the book. But this machine doesn’t need a plate. Just the template…






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4).Digital printing

Digital printing refers to methods of printing a digital-based image directly to a

variety of media at a faster pace and economically.

Leading Manufacturers

Xerox

Cannon

Ricoh

Komori

Kodak

Konica

Samsung

Heidelberg

HP

Kodak

Kyocera

1) Multifunction Printers(MFP)

Office Machine

SOHO

2) Digital Presses

Commercial Machine


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Digital v/s Offset Printing


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Different type of Machines

• speedmaster sm 74




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About the machine

• Production speed up to 15,000 sheets per hour for short throughput times

• Two or four color press with or without wash-up devices attractive range of standard

Features

• Wide range of substrates from lightweight paper to board

• Print press center compact with intelligent start process oriented operator guidance

system for exceptionally user friendly operation

• Highly automated feeder with central suction tape for the widest possible range of

substrates

• Auto plate for fast plate changes and short make ready times

• Compact standard delivery or convenient high pile model

Description

The Speedmaster SM 74 two- and four-color models are the ideal presses for print shops with a professional approach to satisfying growing customer requirements or a desire to grow in a changed market environment. The Speedmaster SM 74 now boasts an extended range of standard features

geared specifically to the needs of these print shops. Combining successful Speedmaster technology with attractive conditions, it offers reliability in production and investment security by delivering high print quality, reliability, and value retention.

The high energy and resource efficiency of the Speedmaster SM 74 make it the most environmentally friendly press in its class. Star System peripherals perfectly coordinated with the press benefit from highly efficient operation and conserve resources.

If you want to more information visit this link:

https://www.heidelberg.com/bnl/en/products/press/sheetfed_offset/speedmaster_sm_74/product_informati

on_5/product_information_2.jsp

https://www.heidelberg.com/bnl/en/products/press/sheetfed_offset/speedmaster_sm_74/product_information_5/product_information_2.jsp

https://www.heidelberg.com/bnl/en/products/press/sheetfed_offset/speedmaster_sm_74/product_information_5/product_information_2.jsp


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• Heidelberg sordz

Specifications:

Type : Offset press Manufacturer : Heidelberg Model : SORDZ (S-Line) Colors : 2 Paper format max : 64×91,5cm Print format max : 62x89cm Press speed max : 10000 Length : 3630 Width : Height : 2140 Weight : 7280

First year of production : 1971 Last year of production : 1974 Country : Germany



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Film Processor

Function-Scanning& Color Separation

Output-It scans the specimen and produce (+)

ve (-) ve copies of the specimen

Japan made

The machine works under infrared rays

Machine type; C-450-ES8

Polymer Machine

Made in Japan

The negative is exposed

And washed using the polymer machine

But we can’t expose very small fonts

We can separate the parts which we want;

But it is not embossing

Plate machine

Brand-Monarch

The positive was printed to a plate. The plate is

sensitive to light and it chemical constituents

can change.

Plate Washer

The plate is being washed & the places in the

chemical side where he letters are not printed

is being washed off;

The letters remain by passing through a gum

cylinder.

When the gum is not used the details of the

template gets damaged.

They also have another washer for fore color

printing called a print bar which helps to

maintain same color weight for CMYK printing.

Five skip machine

One color

The machine I used to print form types.

It has an upper portion of numbering format

and lower printing machine.

It can only print small paper size

Rotary Machine

Can print both side at once

High speed machine

The paper is printed cut into required size and

gathered

Duplex

One color

The roll cut the papers and gathered

They can only use for 27inch template ad it is

default arranged.

Magazine Coder

The paper is printed cut gathered ad folded

which can be specified in the machine.

The output is numbered.

One color

The rate is 3 output per second

SORD machine

One color machine

Heidelberg

Red button long box

Were each paper is given to the machine by a

sucker

Up-original plate (readable)

Lower original plate is copied into a cylinder

(unreadable)

And it is printed to the paper

Cutting Machine

With a sensor

But can only cut limited amount in a time.

They also have another machine without a

sensor but of bigger capacity.


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COMINATION16

Where he printed papers are gathered folded

and given as output

10000 sections per hour

KRAUSE

Three knife trimmer

Template is given first

Where the 3 sides are cut at a time

Final cut

10books at a time

Schedule for operation for changing sizes.

Where relevant sections are clipped

Letter pressing

Heidelberg offset cylinders

1857

Used to print material kept for long time

Made in early age of printing fore color

Long box

For off-set printing for medical envelope

Die Cutter

Where model of required shape is placed and

cut

Half cut machine

Die Cutter 150 years

Used to form stickers of VISA

Even after cutting it can be used for printing

Gathering Machine

There are compartments where each

compartment and sections of a book and is

gathered. Single paper

Enthrone29

Komori

To print tamp

Controlled fully by electronic touch screen

At a time for color 10000 per hour. Japan made


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Section of the printing Press

1). Pre-Press Section

When customer handover the document that needs to print, they need to handover

the document to pre-per section. They can handover it as a hard copy (written

document fro9m hand or printed document which doesn’t have a soft copy) or a soft

copy.

Pre-Per Section responsible for following tasks …

If client handover a hard copy (whatever printed copy or written by hand) they need

to convert it to soft copy by type setting the document. After that they process the document

using desktop publishing software like Adobe InDesign, CorelDraw or something like that. But

in the Government Printing Press of Sri Lanka said they mostly use licensed Adobe software

to do their works.

If client handover a soft copy they don’t need to type setting it. But they need to process the

document using Desktop publishing software to make sure it is ready to print.

2). C2P (Computer to Plate) Section

In this section they create the plate that need to print. Every document that decided

to print use off-set technology should go through this section.

If we talking about plates, printing plates must have ability to transfer an image to

paper, cardboard or other substrates. Printing plates are usually made from metal, plastic,

rubber, paper and other materials. The images, put on the printing plates with photochemical,

photomechanical or laser engraving processes.

Usually, metal printing plates are more expensive but last longer and have greater accuracy.

The offset printing plates used in offset printing are thin (up to 0.3mm), and easy to mount

on the plate cylinder, and they mostly have a mono-metal (aluminum) or less often multi

metal, plastic or paper construction.

Aluminum has been gaining ground for a long time among the metal based plates over zinc

and steel. The necessary graining of the aluminum surface is done mechanically either by sand

blasting, ball graining or by wet or dry brushing. Now a day’s practically all printing plates are

grained in an electrolytic process (anodizing), that is electrochemical graining with

subsequent oxidation.

The imaging, ink accepting coating (light sensitive coating, thickness around 1µm) is applied

to the base material. This material usually a polymer or copper in the case of multimodal

plates (bi metal plates). Light sensitive, Diazo (photo polymer) pre coated aluminum.


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Paper Plates


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Printing plates are now the predominant plates in shops. The image transfer is produced via

the different properties on the surface of such plates after they have been exposed and

developed. The remains of the original light sensitive coating or light sensitive coating

changed by the effect of light are the ink accepting (oleophilic) elements that create the

image.

Chemical changes occur as a result of the penetration of photo effective (actinic) light (light

converting UV rays) causing the light sensitive coating to react differently depending on its

type and structure. There are two type of photochemical reaction when developing the

printing plate;

Hardening of the light sensitive layer by light (Negative plate making)


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Decomposition of the light sensitive layer by light (Positive plate

making)

With positive plate making and conventional printing plate’s production, a positive film is

used as the original that is the non-translucent, blackened section of the film correspond to

the ink accepting surface elements on the plate.

In the case of negative plate making with “negative plates” a negative film is used as an

original that is the ink accepting image areas of the printing plate correspond to the

translucent, light areas on the film. For quality and monitoring during plate making control

elements are copied onto the plates.

3). Computer to Paper Section

In this section we can print our document directly computer to paper. If we

choose laser printing method this is the section for it.in this section they print paper and send

them to finishing section. But some machines that they have could print whole thing using

only one machine. So it we use that machine we don’t need to send them to finishing section.


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4). Plate to Paper Section

This section is the offset printing section. They use plates that made by

computer to plate section to print the documents. This printing technology is efficient if we

have lot of number of prints to print. If not this technology is not efficient to print the

document and it will be expensive.

5). Finishing Section

In this section they finish the document to make sure it looks like what it is.

They bind the document if it is a book. And they cut unwanted spaces in the printing sheets.

This is the last section of printing.


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Customer Handling

The Department of Government Printing, they don’t take private orders like printing private

books, dairies they only accept government printing works. Every document should hand over

for the organization officially. Anyone can’t get in and ask for printing their private needs.

Every single order of that received by the government will be recorded and they protect

maximum privacy of the document.

Company target

"To become the nation's hallmark of excellence in Printing and Publishing"

and

"To provide printing and publishing services with assured quality in time to delight

customers with the help of innovative technology and dedicated staff"


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Memories of field visit


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Thank you …..

Ruvani miss, Chathuri miss and all teachers,

Department of Government printing all workers,

My Friends & all of help for me…!