Ensuring Excellence Through Rigorous Quality Control Processes
At Royle Printing, we take pride in our attention to detail and our commitment to delivering high-quality print products. Our comprehensive quality control processes are designed to ensure that every piece that leaves our facility meets the highest standards of excellence. Here's an inside look at how we maintain our reputation for superior print quality.
Press Quality Control Processes
Our press start-ups begin with clearly defined targets for density, mid-tone dot gain, and print contrast/color. These parameters set the foundation for our quality assurance protocols, which drive our pressmen to consistently monitor and adjust the printing process. To further enhance quality, our presses receive digital information directly from output devices, allowing for automatic presetting of ink keys to the densities specified in the files. Additionally, all our presses are equipped with closed-loop color control systems, which continuously adjust the ink flow to maintain color consistency.
Our quality assurance process mandates pulling one signature every 5,000 runs on web presses and every 1,000 runs on our sheetfed press. The First Piece Approval (FPA) is a critical step, requiring approval from a manager or supervisor before full production continues. Look below to see the key steps and checks involved:
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Density: We monitor ink film thickness to ensure the right amount of ink is applied.
Dot Gain: We measure the change in dot sizes compared to known values to maintain image sharpness.
Print Contrast: We compare the density of solid areas to 75% dot areas to ensure proper contrast.
Trap: We assess the ability of ink to transfer uniformly across multicolored prints.
Hue: We use Certificates of Analysis (COA) from our ink suppliers to confirm the correct ink hue before printing.
CPC Calibration: Our press control consoles are calibrated to disperse the correct amount of ink coverage.
Data Central: We maintain a comprehensive print history and trend data using CIP3 standards.
Bindery Quality Control Processes
In the bindery, we maintain stringent quality control measures managed by experienced operators and managers. Quality pulls are performed every 2,000 pieces on bindery and mail equipment, initiated by the machine operator, with the FPA requiring managerial approval.
We administer pull tests on perfect bound pieces using a machine that measures the PSI required to tear a page out. This is done as part of our FPA process, checking the book at the beginning, middle, and end. Our perfect binder is equipped with a Signature Recognition System that reads the spine’s barcode or print image to verify the correct placement of body forms/pages and the cover. If there’s any discrepancy, the binder shuts down to prevent errors.
Additionally, copy control systems are utilized on all our stitchers, inkjetters, and trimmers. These systems use fiber optics to monitor each individual piece, ensuring accuracy and consistency. Look below for our quality control checklist includes:
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Correct Pagination
Correct Job Number/Lap ID
Correct Insert/Card Placement
Proper Stitch Placement/Clinch
Proper Trim Size
Squareness
No Bleed/Cut Type
Check Crossovers
Inkjet Checklist Completed
Check Book Against Artwork (Binding Dummy provided for all jobs)
Check Job Ticket for Additional Instructions
Commitment to Excellence
At Royle Printing, our quality control processes are not just about maintaining standards—they are about setting them. From press to bindery, every step is meticulously monitored and controlled to ensure that the final product exceeds our clients' expectations. Our dedication to quality is what sets us apart and drives our ongoing success in the printing industry.
Look below for a glimpse into this process!
