Print Control Wizard 20.

User Guide

03 - 2021
 Print Control Wizard

Contents
1. Copyright Notice............................................................................................................................................ 4

2. What is the Print Control Wizard?.................................................................................................................6

2.1. How to Install Print Control Wizard....................................................................................................... 6
2.2. How Does it Work?............................................................................................................................... 6

3. What is a Printing Condition?........................................................................................................................8

3.1. Curves for Controlling Dot Gain............................................................................................................. 8
3.1.1. What is Dot Gain?........................................................................................................................ 8
3.1.2. What is Dot Gain Compensation?................................................................................................9
3.1.3. Dot Gain Compensation Curves...................................................................................................9
3.1.4. PressSync Curves...................................................................................................................... 10
3.1.5. Curve Strategies........................................................................................................................ 12
3.2. Screens for Controlling Ink Lay Down..................................................................................................13
3.2.1. What is Screening?....................................................................................................................13
3.2.2. Types of Screens...................................................................................................................... 14

4. The Print Control Wizard User Interface..................................................................................................... 18

4.1. General Configuration.......................................................................................................................... 18
4.1.1. Connect to Esko server..............................................................................................................18
4.1.2. Preferred Units.......................................................................................................................... 19
4.2. Screens Explorer.................................................................................................................................19
4.3. Curves Explorer.................................................................................................................................. 20
4.4. Printing Conditions Explorer............................................................................................................... 21
4.4.1. Details Pane.............................................................................................................................. 22
4.4.2. Selected Item Pane.................................................................................................................. 23

5. Types of Printing Conditions....................................................................................................................... 25

6. Printing Conditions for Flexibles or Labels.................................................................................................26

6.1. Creating a Printing Condition for Flexibles or Labels...........................................................................26
6.1.1. Printing Condition Configuration Steps..................................................................................... 27
6.1.2. Reviewing the Printing Condition.............................................................................................. 69
6.2. Saving a Report.................................................................................................................................. 69
6.3. Editing Flexibles or Labels Printing Conditions................................................................................... 71
6.3.1. Add Ruling..................................................................................................................................71
6.3.2. Update Curves.......................................................................................................................... 80
6.3.3. Edit White................................................................................................................................. 81
6.3.4. Change Plate Making and Press Calibration Settings................................................................82
6.3.5. Change Screens and Curves..................................................................................................... 82
6.4. Exporting and Importing Printing Conditions..................................................................................... 83

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 Contents

6.4.1. Exporting the Complete Library................................................................................................ 83

6.4.2. Exporting Single Items............................................................................................................. 84
6.4.3. Importing Single Items or a Complete Library.......................................................................... 84

7. Printing Conditions for Corrugated............................................................................................................. 86

7.1. Creating a Printing Condition for Corrugated...................................................................................... 86
7.1.1. Printing Condition Configuration Steps......................................................................................87
7.1.2. Reviewing the Printing Condition.............................................................................................100
7.2. Saving a Report................................................................................................................................. 100
7.3. Editing Printing Conditions for Corrugated........................................................................................ 101
7.4. Exporting and Importing Printing Conditions..................................................................................... 101
7.4.1. Exporting a Printing Condition.................................................................................................102
7.4.2. Exporting the Complete Library.............................................................................................. 102
7.4.3. Importing a Printing Condition................................................................................................ 103
7.4.4. Importing a Complete Library................................................................................................. 104

8. Using a Printing Condition in Your Workflow.............................................................................................105

8.1. Using Your Printing Condition in Imaging Engine............................................................................... 105

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1. Copyright Notice
© Copyright 2020 Esko Software BV, Gent, Belgium

All rights reserved. This material, information and instructions for use contained herein are the
property of Esko Software BV. The material, information and instructions are provided on an AS IS
basis without warranty of any kind. There are no warranties granted or extended by this document.
Furthermore Esko Software BV does not warrant, guarantee or make any representations regarding
the use, or the results of the use of the software or the information contained herein. Esko Software
BV shall not be liable for any direct, indirect, consequential or incidental damages arising out of the use
or inability to use the software or the information contained herein.
The information contained herein is subject to change without notice. Revisions may be issued from
time to time to advise of such changes and/or additions.
No part of this document may be reproduced, stored in a data base or retrieval system, or published, in
any form or in any way, electronically, mechanically, by print, photoprint, microfilm or any other means
without prior written permission from Esko Software BV.
This document supersedes all previous dated versions.
®
PANTONE Colors displayed in the software application or in the user documentation may not match
PANTONE-identified
®
standards. Consult current PANTONE Color Publications for accurate color.
PANTONE and other Pantone trademarks are the property of Pantone LLC. © Pantone LLC, 2015
Pantone is the copyright owner of color data and/or software which are licensed to Esko to distribute
for use only in combination with Studio Visualizer. PANTONE Color Data and/or Software shall not be
copied onto another disk or into memory unless as part of the execution of Studio Visualizer.
This software is based in part on the work of the Independent JPEG Group.
Portions of this software are copyright © 1996-2002 The FreeType Project (www.freetype.org). All
rights reserved.
Portions of this software are copyright 2006 Feeling Software, copyright 2005-2006 Autodesk Media
Entertainment.
Portions of this software are copyright ©1998-2003 Daniel Veillard. All rights reserved.
Portions of this software are copyright ©1999-2006 The Botan Project. All rights reserved.
Part of the software embedded in this product is gSOAP software. Portions created by gSOAP are
Copyright ©2001-2004 Robert A. van Engelen, Genivia inc. All rights reserved.
Portions of this software are copyright ©1998-2008 The OpenSSL Project and ©1995-1998 Eric Young
([email protected]). All rights reserved.
This product includes software developed by the Apache Software Foundation (http://
www.apache.org/).
Adobe, the Adobe logo, Acrobat, the Acrobat logo, Adobe Creative Suite, Illustrator, InDesign, PDF,
Photoshop, PostScript, XMP and the Powered by XMP logo are either registered trademarks or
trademarks of Adobe Systems Incorporated in the United States and/or other countries.
Microsoft and the Microsoft logo are registered trademarks of Microsoft Corporation in the United
States and other countries.
SolidWorks is a registered trademark of SolidWorks Corporation.
Portions of this software are owned by Spatial Corp. 1986 2003. All Rights Reserved.

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JDF and the JDF logo are trademarks of the CIP4 Organisation. Copyright 2001 The International
Cooperation for the Integration of Processes in Prepress, Press and Postpress (CIP4). All rights
reserved.
The Esko software contains the RSA Data Security, Inc. MD5 Message-Digest Algorithm.
Java and all Java-based trademarks and logos are trademarks or registered trademarks of Sun
Microsystems in the U.S. and other countries.
Part of this software uses technology by Best Color Technology (EFI). EFI and Bestcolor are registered
trademarks of Electronics For Imaging GmbH in the U.S. Patent and Trademark Oce.
Contains PowerNest library Copyrighted and Licensed by Alma, 2005 – 2007.
Part of this software uses technology by Global Vision. ArtProof and ScanProof are registered
trademarks of Global Vision Inc.
Part of this software uses technology by Qoppa Software. Copyright © 2002-Present. All Rights
Reserved.
All other product names are trademarks or registered trademarks of their respective owners.
Correspondence regarding this publication should be forwarded to:
Esko Software BV
Kortrksesteenweg 1095
B – 9051 Gent
[email protected]

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2. What is the Print Control Wizard?

The Print Control Wizard is a set of tools in the Color Pilot application, designed to help you optimize
your print quality.
Based on your exact production workflow, your current print quality and the standard you want to
print towards, the Print Control Wizard will calculate the best possible screens and curves that you
can use to achieve great results on press.
This will help you avoid common problems, for example a lack of smoothness in the transition from
highlights to paper, or from shadows to solids, and will make getting good printing quality time after
time easier.

2.1. How to Install Print Control Wizard

The Print Control Wizard is completely integrated in the Color Pilot Application, Esko's default
application for creating color data (inks, proofer profiles, press profiles…).
To be able to use all functionality within the Print Control Wizard, you need to also install Curve Pilot on
the same workstation.
You can install both Color Pilot and Curve Pilot from the Imaging Engine installation DVD. For more
information, please see the Imaging Engine Installation and Configuration chapter of the Imaging
Engine user guide. You can also find a direct link to the installation documentation in the DVD itself.

Note:
Until version 18.1.1, Print Control Wizard was a separate application, with its own installation procedure.
If you are using version 18.1.1 or older, please use the Print Control Wizard 18 or 18.1 user guide: https://
www.esko.com/en/support/product?id=Print%20Control%20Wizard

2.2. How Does it Work?

The Print Control Wizard will help you achieve the best possible printing quality in the following way:
1. Record all the production settings you are using.
During the setup, you enter all of the settings you use in your production workflow (anilox, plate
type, consumables... including the standard you want to print towards).
See Printing Condition Configuration Steps on page 27.
2. Fingerprint your press using the Print Control Wizard.
The Print Control Wizard guides you through the steps necessary to make and interpret a print
sample for your ink set.
Based on your input and the results of the print sample, it gives you the best curve and screen to
use for your inks.

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See Plate and Press Calibration on page 28, White on page 39 and Screens and Curves on page
47.
3. The Print Control Wizard generates a printing condition containing curve(s) and screen(s) tailored
to your production workflow.
See What is a Printing Condition? on page 8.
4. You use that printing condition when RIP'ing your jobs with Imaging Engine to get great results on
press.
See Using a Printing Condition in Your Workflow on page 105.

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3. What is a Printing Condition?

The Print Control Wizard will guide you in creating a printing condition. This printing condition will:
• describe your exact production workflow (plate-making workflow and printing setup) and the way it
prints,
• include the standard you want to print towards (an ISO standard, linear printing...),
• result in the best possible curves and screens to achieve the quality of that standard with your
production workflow.

Important:
After making a printing condition, you should use it every time you print with that production workflow.
If you make changes to your production workflow (for example you print on a different substrate, or
you switch to a different ink vendor), we recommend you edit your printing condition or make a new
printing condition and use that instead.

3.1. Curves for Controlling Dot Gain

3.1.1. What is Dot Gain?

When printing a job, the dots tend to print larger on the press than on the plate, which makes the
output darker than the original file.

Original job

 
 

Plate

 
 

Print

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This is due to different factors:

• the type of ink: the more fluid the ink is, the more it will spread under pressure of the press.
• the type of substrate: paper with a rougher and more porous surface (like uncoated paper) reflects
less light, making the printed area look darker.
• the type of press: flexo presses have a high dot gain as they put significant pressure on the
substrate.

3.1.2. What is Dot Gain Compensation?

To compensate for dot gain and have the printed output look like the original file, you use dot gain
compensation (DGC). This consists in making the dots on the plate smaller, so that with dot gain they
print to the correct density.

Dot on plate Dot on press

 
 

Without DGC

 
 
 
 
With DGC
 
 

You apply dot gain compensation by using a curve, which can be:
• a classic dot gain compensation curve (also called DGC curve), which defines which percentage to
use on plate for each desired percentage on press.
See Dot Gain Compensation Curves on page 9.

• a PressSync curve: PressSync curves are predefined compensation curves that can cover the dot
gain compensation needs of most presses, while significantly reducing the complexity of dot gain
compensation in workflows.
See PressSync Curves on page 10.
The Print Control Wizard generates flexible PressSync curves, that contain additional parameters
to address specific flexo printing challenges in the highlights and shadows.
See Flexible PressSync Curves on page 11.

3.1.3. Dot Gain Compensation Curves

Traditionally, you apply dot gain compensation by using a dot gain compensation curve, which defines
which percentage to use on plate for each desired percentage on press.

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In the example below, you see how a press prints without any dot gain compensation in the dot gain
curve at left: a 20% on the plate prints to 57% on press. 57% on the plate would print to almost 90% on
press.
At right, you see the dot gain compensation curve used to make the press print to the expected value
in the job: to print a 57% on press, a 20% will be used on the plate. To print a 20% on press, you would
need about 5% on the plate.

press plate

plate press

Dot gain curve Dot gain compensation curve

Creating a Dot Gain Compensation Curve

You can create dot gain compensation curves in Curve Pilot (for more information, see the Curve Pilot
User Guide: https://www.esko.com/en/support/product?id=Curve%20Pilot).
Dot gain compensation curve files have the .dgc extension.

3.1.4. PressSync Curves

Another type of compensation curve is the PressSync curve.
PressSync curves are predefined compensation curves that can cover the dot gain compensation
needs of most presses, while significantly reducing the complexity of dot gain compensation in
workflows.

Slope and Mid-tone Compensation

Curves are defined by a letter and a number.
• The letter (A to H) describes how the press behaves in the highlights and shadows (the slope): an
A curve makes the press print darker in the highlights and lighter in the shadows (for presses who
have the opposite problem), while an H curve, on the contrary, makes the press print lighter in the
highlights and darker in the shadows.
 

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An E curve is halfway in between and has a straight slope: it corrects the output the same way
throughout the range. Use it for presses whose output is consistent in the highlights, mid-tones and
shadows.

• The number indicates how much the 50% dot (mid-tone) prints to: an E20 curve compensates the
50% dot to 20%, while an E70 curve compensates 50% to 70%.
 

Creating a PressSync Curve

You cannot create PressSync curves, they are predefined. There are 400 different PressSync curves, to
match most dot gain compensation needs.
If you wish, you can see each PressSync curve on a graph in PressSync Pilot (for more information, see
the Curve Pilot User Guide: https://www.esko.com/en/support/product?id=Curve%20Pilot).

Flexible PressSync Curves

A flexible PressSync curve is a specific type of PressSync curve made for managing the tone
reproduction of flexo printing environments.
On top of the letter and number defining the standard PressSync curves, a flexible PressSync curve
contains options to address specific flexo printing challenges.

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Reproducing Highlights
Flexo highlights are often too sharp against the substrate and/or unstable, which can be dicult to
adjust using standard PressSync curves:
• For some ink/substrate combinations, the contrast between the substrate and the lightest printed
tone is high: even a very small halftone dot leaves a strong ink impression.
• On top of that, very small dots often don't print in a stable way on flexible substrates, so the
minimum dot size is increased to get stable highlights.
Flexible PressSync curves contain parameters to address those highlight issues.

Reproducing Shadows
The most common issue with shadows in flexo is tone reversal, where a high percentage (for example
95%) prints darker than the solid (100%).
Flexible PressSync curves also contain parameters to address tone reversal issues in the shadows.
You can find more information about flexible PressSync curves parameters in the Curve Pilot
documentation. See https://www.esko.com/en/support/product?id=Curve%20Pilot.

Note: Adjustment curves generated by the Print Control Wizard are flexible PressSync curves. They
are embedded in a curve strategy (.icpro) to allow the use of multiple curves in a Print Condition.

Note: The flexible options for highlights and shadows are displayed between brackets in the Print
Control Wizard, for example F35 (Min3.38%,h4,s6)

3.1.5. Curve Strategies

Dot gain within the same print job can vary depending on the screening parameters, inks, and other
factors.
A curve strategy allows you to combine different DGC curves and/or PressSync curves in 1 file (.icpro). A
complete curve strategy contains a compensation curve for every practical combination of inks, ruling,
screens, and/or any other operating parameters affecting dot gain used on your press.
You do not need a separate curve strategy for each new print job. Well-designed strategies are
applicable to many jobs as long as the printing conditions are similar.

Note:
Curve strategies (.icpro) generated by the Print Control Wizard contain a PressSync curve per ruling
that is added to your printing condition.
The PressSync curve contains a curve per ink present in the printing condition.

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3.2. Screens for Controlling Ink Lay Down

3.2.1. What is Screening?

When printing an image on press, each ink (Cyan, Magenta, Yellow, Black and any additional ink) is laid
out separately on the substrate, and the super-imposition gives the final colors.
At a high detail level, the press can either print ink or not print ink, so to create differences of color
intensity within one ink, you use a small scale pattern of dots of varying size, called a screen.
 

 
When viewed from a regular distance, this pattern looks like a lighter or darker shade of that color,
depending on how big the dots are (what percentage of the area they cover).
 

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Screen Ruling
The screen can also be coarser or finer, so that you have to be more or less far away to see it as shades
of a color. This depends on how many lines of dots can fit in a certain measurement. This is expressed
in lines per inch (lpi), lines per centimeter (lpcm) or lines per millimeter (lpmm), and is called the screen
ruling.
 

 
A low screen ruling as below left looks very coarse, and the quality improves as the screen ruling gets
higher.
 

3.2.2. Types of Screens

The Print Control Wizard will generate custom screens for your production workflow, so that you get
the best possible printed results.
All screens generated by the Print Control Wizard use 1 or more Esko screening technologies:
• Pixel+ for surface screening in solids
• Pixel+ for Crystal dot shape:
• FM in the highlights
• support dots
Depending what Esko screening technologies are combined, you get 3 types of screens: Crystal,
Crystal C or Crystal NP.

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Crystal and Crystal C Screens

The Crystal and Crystal C screens are part of Esko’s latest screening family, were the pixel+ technology
is used throughout the tonal range.
Each dot is made of individual pixels, that are “boosted” on the CDI to make printable dots.
Surface screening in solids, FM in the highlights and support dots are optional, but could be added to
further improve quality.
 

 
Crystal screens use the Pixel+ technology throughout the tonal range.
 

 
Crystal C screens use solid dots in the highlights, and transition to Pixel+ dots for the rest of the tonal
range.
 

 
Crystal C screens can produce finer highlights, but Crystal screens can be more stable. The optimal
screen to use depends of your particular production workflow.
When using Crystal/Crystal C screens, you don't need to use object-based screening (different screens
for individual objects in your file), as they give good results in all areas:
• They provide a smooth transition from the solids into the shadows and mid-tones, with reduced dot
bridging.

   

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dot bridging with a circular dot no dot bridging with a crystal screen

• They produce stable highlights that fade out to zero more smoothly than with other screening
technologies.

Crystal NP screens
The Crystal NP screens are using classic dot shapes in the tonal range.
To further improve quality, surface screening in solids, FM in the highlights and support dots could be
optionally added.
You can choose between:
Circular (short name: C)
Circular dots grow continuously circular until 100%. They are commonly used in flexography.

This dot shape is also called Circular (Euclidean), and Print Control Wizard screens using this dot
shape are called Crystal NP C (Circular).
This dot gives good results in many situations. However in some printing conditions the holes in the
shadows can fill in, which can result in unstable or high dot gain, and cause a loss in tonal range.
If you experience this, you should choose the Round Fogra dot instead.
Elliptical (short name: E)
This dot shape is a more elliptical version of the Round Fogra dot.

For these dots, the first touching point is around 35%. Between 35% and 65%, a chain is formed with
the same orientations as for the Round Fogra dots.
Print Control Wizard screens using this dot shape are called Crystal NP E (Elliptical).
Double Circular (short name: F)

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Screens using the Double Circular dot have circular dots in the highlights and mid-tones, and circular
holes in the shadows.

Print Control Wizard screens using this dot shape are called Crystal NP F (Double Circular).
Note that this screen can cause irregular ink bridging ("bridges" between dots) around the mid-tones,
which can give unstable dot gain in that tonal range.
If you experience this, you should choose the Round Fogra dot instead.
Round Fogra (short name: R)
The Round Fogra dot closely resembles the Elliptical and Circular dots, and can be used the same way.
It goes from a round dot to a round hole, with a square/diamond shape in the mid-tones.

As with elliptical dots, the touching of the dots at the four corners at 50% (leading to a 50% intensity
jump) is avoided by using a more elongated dot shape so that the dots first touch around 45% forming
a chain and touching for the second time around 55%. This causes less artefacts and less dot gain
when printing.
The Round Fogra dot can be used for virtually all printing processes.
Print Control Wizard screens using this dot shape are called Crystal NP R (Round Fogra).

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4. The Print Control Wizard User Interface

The Print Control Wizard is completely integrated in the Color Pilot application, Esko's application for
creating and managing color data (inks, proofer profiles, press profiles…).
In this user guide we only discuss the items related to the Print Control Wizard.
Please consult the Color Pilot user guide for more details on the full interface and features: https://
www.esko.com/en/support/product?id=Color%20Pilot

Note:
Until version 18.1.1, the Print Control Wizard was a separate application, with its own installation
procedure.
If you are using version 18.1.1 or older, please use the 18 or 18.1 user guide: https://www.esko.com/en/
support/product?id=Print%20Control%20Wizard.

When you have the correct licenses, you will see in the navigation pane (on the right side of the user
interface) a view called Screens and Curves, containing 3 categories:
• Screens. See Screens Explorer on page 19.

• Curves. See Curves Explorer on page 20.

• Printing Conditions. See Printing Conditions Explorer on page 21.

4.1. General Configuration

4.1.1. Connect to Esko server

All data generated by Print Control Wizard should be stored on the Automation Engine server, or the
Imaging Engine server if no Automation Engine is present.
Why?
• To be able to use the curves, screens and printing conditions in Imaging Engine.
• The centralized data can be used by other Esko applications, for example editors (ArtPro+, Plato…)
and Pilots.
• All data is part of the Automation Engine full back up.
To connect to an Esko server:
1. Go to Edit > Preferences.
2. Select the Servers tab.
3. In Server Name, enter the name of your Automation Engine Server.
4. Enter your User Name and Password.
5. Click the Check Connection button.

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If the connection is successful, you will see a green dot with the text Connected
6. Select the Database tab.
7. Select Obtain from Esko Server and verify if the correct name of your Automation Engine is
mentioned.
In Path Details, you should see that the Color, Curves and Screens databases are now located on
the chosen server.
8. Close the Preferences dialog and restart Color Pilot.

4.1.2. Preferred Units

1. Go to Edit > Preferences > Test Charts.
2. Choose whether the Units shown in the user interface should be Decimal or Imperial.

4.2. Screens Explorer

When you select Screens in the navigation pane, you will see a list of all screens available on your
server.
For each screen, you can see:
• the Screen Name,

• a unique Code (short name),

• the Kind of screen it is (Crystal, Static, Custom or HD Flexo),

• any Keywords you assigned to the screen.

The library can contain 4 kinds of screens, each with his own specific icon:
• Green icon: Static screens, from Automation Engine/Imaging Engine installation
• Blue icon: HD Flexo screens generated by the Esko application HDFlexo Screens
• Violet icon: Custom screens generated by the Esko application ScreenManager
• Orange icon: Crystal screens generated by Print Control Wizard

Note: The Screens explorer doesn't have an icons view, only a list view and grouped list view. For more
information, see the chapter Views in the Color Pilot user guide: https://www.esko.com/en/support/
product?id=Color%20Pilot

From the Screens Library, you can:

• delete a screen: right-click it and select Delete (or select it and press the Delete key) then click Yes
to confirm.
• Rename a screen: right-click it and select Rename (or select it then click its name), then enter a
new name and click Enter.
• Export a screen (to share with another Color Pilot): see Exporting Single Items on page 84.
• Import a screen that was previously exported: see Importing Single Items or a Complete Library on
page 84.
• See if the screen is used in another object: right-click it and select Show Links.

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• see where a screen is used: right-click it and select Show Links to see which printing condition use
it.
• add/remove keywords to find your screen more easily: see the chapter Keywords in the Color Pilot
user guide: https://www.esko.com/en/support/product?id=Color%20Pilot.

Note:
• Static (green) and Crystal (orange) screens are always locked ( ), you cannot delete, rename, export
or import them. See also Exporting and Importing Printing Conditions on page 83.
• You cannot rename HD Flexo screens (blue), as they are predefined in the HD Flexo database.
• If the screen has a link to another object (for example, it is used by a printing condition), you will see
a warning showing where it is being used, and you will not be able to delete or rename it.

4.3. Curves Explorer

When you select Curves in the navigation pane, you will see a list of all curves available on your server.
For each curve, you can see:
• the Curve Name,
• the Kind of curve it is (curve, curve strategy, PressSync curve set),
• any Keywords you assigned to the curve
The library can contain 3 kinds of curves, each with his own specific icon:

• Curve : a single curve for dot gain compensation, see Dot Gain Compensation Curves on page 9
• PressSync Curve set : set of predefined compensation curves, see PressSync Curves on page 10
• Curve Strategy : a group of curves and rules for automatic curve selection, see Curve Strategies
on page 12

Note: The Curves explorer doesn't have an icons view, only a list view and grouped list view. For more
information, see the chapter Views in the Color Pilot user guide: https://www.esko.com/en/support/
product?id=Color%20Pilot

From the Curves library you can:

• Open a curve in the Curve Pilot application: right-click it and select Open in Curve Pilot.
To know how to view and edit, see the Curve Pilot user guide: https://www.esko.com/en/support/
product?id=Curve%20Pilot

Note:
We strongly advise against editing curves and curve strategies created via the Print Control Wizard
in Curve Pilot.
Curve Pilot is an expert tool with a lot of functionality that is not needed and therefore not
supported by the Print Control Wizard.
Wrong usage of the tools could generate issues in your Printing Condition.
Use Update Curves in your printing condition instead. See Update Curves on page 80.

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• delete a curve: right-click it and select Delete (or select it and press the Delete key) then click Yes
to confirm.
• Rename a curve: right-click it and select Rename (or select it then click its name), then enter a new
name and click Enter.
• Export a curve (to share with another Color Pilot): see Exporting Single Items on page 84/
• Import a curve that was previously exported: see Importing Single Items or a Complete Library on
page 84.
• See if the curve is used in another object: right-click it and select Show Links.
• add/remove keywords to find your curve more easily: see the chapter Keywords in the Color Pilot
user guide: https://www.esko.com/en/support/product?id=Color%20Pilot.

Note: If a curve has a link to another object (for example, it is used in a curve strategy), you will see a
warning showing where it is being used, and you will not be able to delete or rename it.

4.4. Printing Conditions Explorer

When you select Printing Conditions in the navigation pane, you will see a list of all printing conditions
available on your server. The library can contain:
• Printing conditions from older versions (18.1.1 or lower): these are greyed out and locked ( ), they
cannot be edited.

•
Unfinished printing conditions ( ): these cannot be used in production yet, but can be edited.

• Finished printing conditions: these are ready to use in production, and can be edited.

When you see this icon , the printing condition has an unfinished task (you have saved your progress
in a wizard session but not completed the wizard).
The library also shows the essential parameters for each printing condition, if you already filled them
in:
• Ink Set: the ink set for which you made the printing condition.
This is only filled in for printing conditions made for labels or flexibles, as printing conditions made
for corrugated are not made for a pre-determined ink set (you typically enter parameters for all inks,
and you can enter different parameters for specific inks if desired).

• Application: this can be Flexibles, Labels or Corrugated, depending on the type of printing
condition you made.

• Substrate: the substrate for which you made the printing condition (this also depends on the type
of printing condition you made).

• Plate type: the plate type you use in your printing process, and for which you made the printing
condition.

• Date Modified: the date and time at which you last made changes to the printing condition.

• Keywords: any keywords associated with the printing condition (see the Keywords chapter in the
Color Pilot user guide: https://www.esko.com/en/support/product?id=Color%20Pilot).

Tip: You can sort the printing conditions according to a parameter: click on the header of that column.

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Note: The Printing Conditions explorer doesn't have an icons view and grouped list view, only
a list view. For more information, see the Views chapter in the Color Pilot user guide: https://
www.esko.com/en/support/product?id=Color%20Pilot.

From the library you can:

• Open a printing condition: right-click it and select Open, or double-click it.
• delete a printing condition: right-click it and select Delete (or select it and press the Delete key),
then click Yes to confirm.
• Rename a printing condition: right-click it and select Rename (or select it then click its name), then
enter a new name and click Enter.
• Duplicate a printing condition: right-click it and select Duplicate then enter a new name and click
Enter.
• Export a printing condition (to share it with another Color Pilot application): see Exporting Single
Items on page 84.
• Import a printing condition that was previously exported: see Importing Single Items or a Complete
Library on page 84.
• Show more details about the printing condition. See Details Pane on page 22.
• Save a report of that printing condition. See Saving a Report on page 69.
• Update curves of that printing condition. See Update Curves on page 80.

Note: This is only applicable to printing conditions for flexibles or labels, not for corrugated.
• Add a ruling to that printing condition. See Add Ruling on page 71.

Note: This is only applicable to printing conditions for flexibles or labels, not for corrugated.
• Remove unfinished task: cancel an unfinished task ( ) you saved for the printing condition.
• Add/remove keywords to find your printing condition more easily: see the Keywords chapter in the
Color Pilot user guide: https://www.esko.com/en/support/product?id=Color%20Pilot.

Note: Printing conditions from older versions (18.1.1 or lower) are view only, you can only show details
and add/remove keywords.

4.4.1. Details Pane

To quickly get more information about a printing condition, you can open the details pane: right click a
printing condition and select Show Details. You can then see more details on the right-hand side.

All Printing Conditions

For all printing conditions, you can see:
• the printing condition's Name,

• the printing condition's Status (whether it's ready for production or not). When the printing
condition is Ready for Production, you can use it in Imaging Engine.

Flexibles and Labels Printing Conditions

For flexibles or labels printing conditions, you can also see:
• which press you made the printing condition for (Press Brand),

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• which Substrate you made the printing condition for,
• the Printing Standard you are printing towards.
• your Imager Type,
• the Exposure Type you are using,
• the Plate type you are using.

Note: You can open the Plate Making parameters from here: click Open Plate Making.

If you have already determined screens and curves for your printing condition, you can also see:
• the Screens and Adjustments Curves saved in your printing condition,
• a table that shows, for every ink in the printing condition's ink set:
• the ink Name and Ink Book,
• the screen Code (for example crs01, crs02 …),
• the Curve's short name (excluding the advanced parameters) for each ruling that is defined.

Note: You can open the Screens and Curves parameters from here: click Open Screens and Curves.

Corrugated Printing Conditions

For corrugated printing conditions, you can also see:
• which press you made the printing condition for (Press Brand),
• which Board Liner material you made the printing condition for,
• your Imager Type,
• the Exposure Type you are using,
• the Plate type you are using.

Note: You can open the Plate Making parameters from here: click Open Plate Making.

If you have already determined a screen for your printing condition, you can also see a table that shows,
for every ink defined in the printing condition:
• the ink Name and Ink Book,
• the Screen Name (the screen code and full screen name of the screen to use for that ink).

Note: You can open the Press and Inks parameters from here: click Open Press and Inks.

Unfinished printing conditions ( ) will only show details from the parts that already have been
completed.

Tip: You can leave the details pane open when you navigate through the printing conditions. The
details pane can be closed by clicking the X icon in the top right corner.

4.4.2. Selected Item Pane

When you select a printing condition in the Printing Conditions explorer, you can see some basic
information about it in the Selected Item pane, in the application's lower left corner:

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• the printing condition's name,

• the date (and time) it was created on, and modified,

• any keywords you have associated with this printing condition,

• any description you have entered for this printing condition.

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5. Types of Printing Conditions

Depending on your license(s), you can create up to three types of printing conditions, corresponding
to three different flexo printing workflow applications (the type of jobs and substrates that you usually
work on):
• printing conditions for flexibles, if you are printing on flexible packaging material (for example for
plastic bags or pouches),

• printing conditions for labels, if you are printing labels (on a narrow web substrate),

• printing conditions for corrugated, if you are printing on corrugated material (for example
packaging cardboard).
If you already had a previous version of the Print Control Wizard (18.1.1 or earlier), you may also still have
legacy printing conditions (for flexibles and/or for labels).
You can still use these printing conditions in production, but you will not be able to edit them anymore.
You can see all of these printing conditions in the Printing Conditions Explorer.

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6. Printing Conditions for Flexibles or Labels

6.1. Creating a Printing Condition for Flexibles or Labels

If you are printing on flexible packaging material (for example for plastic bags or pouches), you should
create a printing condition for flexibles.
If you are printing labels (on a narrow web substrate), you should create a printing condition for labels.

Note: To create a printing condition for flexibles and/or labels, you need to have the respective
corresponding licenses.

1.
In the Printing Conditions library, click the New Printing Condition button in the bottom
toolbar.
2. In the New Printing Condition dialog:
a) Enter the Printing Condition Name you want to use.
We recommend you use a descriptive name, that includes some of your workflow's key settings,
for example Press Type - Plate Type - Substrate.
b) Select the Application of your flexo printing workflow (the type of jobs and substrates that you
usually work on).

Note: Depending on your license, you may see one or more options here.

• Select Flexibles if you are printing on flexible packaging.

• Select Labels if you are printing labels (on a narrow web substrate).

Note: The selection of the Application is not just informative, it influences some of the steps
during calibration: different choices in drop down menu’s, charts will be adapted in size and
design, …
c) Select the Substrate. See Substrate on page 42
d) Select the Ink Set. See Ink Set and Printing Standard on page 43

Note: It is still possible to change the substrate and ink set after this dialog is closed.
e) Click OK. A new printing condition is created, and the configuration steps are shown.

Note: The printing condition is immediately saved into the database.

3. Complete all configuration steps: see Printing Condition Configuration Steps on page 27
4. After finishing the last configuration step Screens and Curves, you can:
• Have a final look at the results and parameters of the printing condition: see Reviewing the
Printing Condition on page 69
• Create a detailed report of the printing condition: see Saving a Report on page 69

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Over time, as your equipment ages and your production fluctuates, you may need to adapt your printing
condition, see Editing Flexibles or Labels Printing Conditions on page 71.

6.1.1. Printing Condition Configuration Steps

At the top, a banner displays the status of the printing condition and a brief description of the selected
configuration step.
Below the banner you see an overview of all configuration steps:
• General on page 28
• Plate and Press Calibration on page 28
• White on page 39
• Substrate on page 42
• Ink Set and Printing Standard on page 43
• Plate Making on page 43
• Press Settings on page 45
• Screens and Curves on page 47
To navigate between the configuration steps, you have 2 options:
• Select a configuration step
•
Click the navigation arrows on the left and right of the pane:
Unfinished printing conditions have an indicator next to each step:
• : all mandatory parameters are completed
• : still need to complete some or all mandatory parameters
• : configuration step is not available until some mandatory parameters in previous steps are
completed

Note:
• Mandatory parameters in the configuration steps are marked with a grey check mark . All need to
be green before the configuration step is marked completed.
• The progress of some steps (selection options, charts…) depend on the mandatory parameters
from previous steps. Changing a parameter will require to redo the step.

Note:
It is not possible to edit any of the selection lists in the printing condition (substrate type, plate type…).
Only parameters that have been tested and approved, can be selected.
The selection in step x, can limit the selection possibilities in 1 of the next steps.
The activated licenses can also influence the selection possibilities.

At any point in the process you can stop working on your printing condition and continue later. Use the
buttons Close and Quit Now and Continue Later. Don’t forget to Save when asked.
When you are ready to continue, open the printing condition by right-clicking it and selecting Open, or
by double-clicking on it. The first step that is incomplete will automatically be selected, to remind you
where to continue.

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Note: When you open a finished printing condition, the interface will be a little different. See
Reviewing the Printing Condition on page 69

If you want to remove your latest modifications in the printing condition, click the Revert button in the
bottom tool bar. Be aware that ALL modifications until the latest save action will be removed.
We recommend to regularly save changes (for example after every step) to make better use of Revert
and avoid unnecessary loss of time and data.

General
The first configuration step in the list shows the Application that has been chosen in the New Printing
Condition dialog. It can no longer be changed.
See Creating a Printing Condition for Flexibles or Labels on page 26 or Creating a Printing Condition for
Corrugated on page 86.
You have the opportunity to enter a Description and add/remove Keywords, but this is not mandatory.

Note:
Keywords added via the Printing Conditions Explorer, will also be visible here.
See the chapter Keywords in the Color Pilot user guide: https://www.esko.com/en/support/product?
id=Color%20Pilot

Plate and Press Calibration

In this configuration step you will verify the quality of your plate making and determine the best
possible screening dot (dot shape) and surface screening (solids) for your printing condition.
Note:

Note: Screen setup for the highlights will be determined in the last configuration step Screens and
Curves.

To complete this configuration step, you have 3 options:

1. Start a new calibration on page 28
Select this option if you want to be guided step by step through the calibration.
2. Copy the calibration from another Printing Condition on page 38
Select this option if you know that the same settings from an existing printing condition can be
used for your new printing condition .
3. Define the plate screening settings manually on page 38
Select this option if you know what settings to select, without using the wizard, for example based
on knowledge and tests from outside the Print Control Wizard, settings received from an external
partner, etc.

Start a new calibration

The plate and press calibration wizard consist of 5 steps, displayed in this way:

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Note:
When you Quit to Continue Later, the completed steps will be colored. The step where you will
continue from, is also colored and the text is darkened:
 

 
To continue the configuration, click Click here to continue calibrating your plate making and press.

1. To start the wizard, click Click here to start calibrating your plate making and press.
2. Select Start a new calibration
3. Click Next in the lower right corner
4. Create two test charts:
a) Click Save Charts...
b) Specify the folder where you want to save and click Select Folder
Two files are created in the selected folder: PlateAndPressCalibrationA.LEN and
PlateAndPressCalibrationB.LEN
Example of chart A:
Will be used to determine the dot shape, surface screening and pixel boost factor
 

 
Example of chart B:
Will be used to verify the plate quality and to determine the dot shape
 

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Note:
• This wizard creates different charts for Labels and Flexibles. It is possible to re-use the same
files for other Plate and Press calibrations, but make absolutely sure that you use the correct
chart for Labels and Flexibles!
• The Chart will always be saved as a LEN file, no other formats possible.

5. Click Next in the lower right corner

6. Image the plate on CDI according to your company's Standard Operating Procedures, using the 2
LEN test charts:
• Chart A:
Image several times using a different boost factor.
To automatically create a series, use the step test option in the Grapholas Exposer software
from the CDI.

Note:
• For more information about setting up step test on a CDI Crystal , click Learn more about
setting up a Step Test. For more information about setup on a CDI Spark, contact Esko
Support.

• Create as many copies as your plate size can contain.

• Chart B:
Image the chart once.

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Note:
• Make sure that charts A and B are on the same plate, so they will be printed together.
• Position the charts in the print direction on the plate (Esko logo printed first)
 

7. Check the Mask quality on chart B

 

 
a) Check your plate
• use a mask densitometer (such as the Techkon DENS or the Techkon T120)
• put the unexposed plate on a light table
• click Learn more about evaluating this area.

• compare your result to the value that was found as good quality during installation of the CDI
b) Select the Check Plate Relief and Masked Image area in the preview image of the chart.
c)
Accept if the result matches the reference, or Reject if the result doesn't match.

Note: As the acceptance of this area also includes the Plate Relief, you can wait to click Accept
until you finished the Plate Relief test after exposing the plate.

8. Expose and process the Plate according to your company's Standard Operating Procedures

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9. Check the Dot Fail Test on chart B

a) check your plate

• use a simple magnifying glass
• check the center and lower row
• the smallest number where all dots are in position gives the resulting value. For more
information, click Learn more about evaluating this area

• compare to the value that was found as good quality during installation of the CDI (for newer
Software-versions this is being recorded within the software)
b) Select the Dot Fail area in the preview image of the chart
c)
Accept if the result matches the reference, or Reject if the result doesn't match.
10. Check the Plate Relief on chart B
 

 
a) check your plate
• use a micrometer
• measure the plate height on an area that was intensively exposed (solid, MC16p, MG25, 50%)
• measure the floor height in the area marked ‘Relief’
• calculate the relief = plate height – floor height. For more information, click Learn more about
evaluating this area

• compare to the value that was found as good quality for your production

Note:
• If the relief is too high (low floor), the highlight dots will print unstable.
• If the relief is too low (high floor), the floor will start to print in some areas (dirty print).

b) Select the Check Plate Relief and Masked Image area in the preview image of the chart
c)
Accept if the relief is not too low or too high, or Reject if the result doesn't match.

Note: This area can only be accepted if the Plate Relief and Mask quality tests are positive

11. Check the Dot Isolation (single dot test) on Chart B

 

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a) check your plate
• use a magnifying glass
• verify the 10 squares, each square contains 100 dots of a certain size and is marked by a
number (the number indicates the size of the dots in the square: 16 = 4x4 pixels)
• the smallest number where all dots of 1 square are equal in shape and size, gives the resulting
value For more information, click Learn more about evaluating this area

• compare to the value that was found as good quality during installation of the CDI (for newer
Software-versions this is being recorded within the software)
b) Select the Check Dot Isolation area in the preview image of the chart
c)
Accept if the result matches the reference, or Reject if the result doesn't match.
When your plate quality is ok, you accepted all 3 areas and it is possible to continue with the next
step.
 

 
If you rejected one or more checks, you cannot continue to the next step
 

 
Troubleshoot your plate making process and repeat the test. When the new test is positive, you can
change the state from Reject to Accept for that area.
12. Click Next in the lower right corner
13. Make a Print using this plate, according to the Printing Condition and your company's Standard
Operating Procedures.

Note: We recommend to print with cyan or magenta ink.

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Note:
When you will evaluate and select the best screen for your printing condition, it is important to know
if the screens changed during printing (act unstable).
We therefore recommend:
• after reaching printing conditions (= first ok sheet), print 50 to 100 meters
• starting from the first ok sheet, select minimum 3 copies (we advise to select 5) that represent
the complete print run: begin, middle and end

14. Click Next in the lower right corner

15. Verify the print
a) Check the Slur and Impression (pressure) marks on the print
• use a magnifying glass
• ALL marks on the print should be ok, to avoid left-right; top-bottom differences

• To know how to evaluate the marks, click Learn more about evaluating and verifying print
quality

Note: Also verify the other copies. If 1 or more copies are not ok, they should be replaced by a
copy from that same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with
the press operator and reprint.
b)
Accept or Reject
When your print quality is ok, it is possible to continue to the next step.
 

 
16. Click Next in the lower right corner
17. Choose the best solid (surface screening)
The best solid is achieved by a combination of a surface screening type and the correct pixel boost
factor.
a) Evaluate, by using the pixel boost step test with chart A
 

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b) Compare all solid patches of the charts A (see note) and select the best printed solid based on 3
criteria:
• Trailing edge
• Smooth ink lay down
• SID (Solid Ink Density)
 

 
1. First eliminate all solids that show Trailing edge and Smooth ink lay down issues, generated
by a wrong pixel boost value. Use a magnifying glass.
2. Measure the density of the remaining solids. Use a classic densitometer or
spectrophotometer (for example XRite eXact).
3. Select the solid with the highest value + see what pixel boost value and surface screening
that was used.

Note:
Several copies of chart A were placed on the plate, each having its own pixel boost factor. Each
chart A contains 4 solids. 3 solids contain a surface screening and should show a different
printing result.
The classic solid will be identical on every chart, as the pixel boost has no effect on it (no surface
screening).
for example 5x chart A on plate x 3 solids with surface screening per chart + 1 classic solid = 16
different results.

Note: For more information, click Learn more about selecting the boost factor and screen
technology.
c) Check if your selection is also not causing any issues in:

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1. Text, negative text and negative lines

 

 
2. Smoothness of the transition into the Solid (no tonal jumps)
 

Note:
• MG34 and MG45 have several gradients in chart A. It is not necessary that all gradients have a
smooth transition.
• The gradient named ‘Crystal’ is using MCWSI.

d) Check on the other copies you selected from your print run, if your selection shows similar
results, without issues!
e) Select the Surface Screening from the pull-down menu in step 1: MCWSI, MG34, Solid or MG45
f) Enter the Solid Density and select the Density standard you use on your measurement device
(ANSI A, DIN, …), not mandatory.
g) Enter the Boost Factor (Pixel Boost value) in step 3

Note: When you select the Surface Screening, ‘Use pixel boost’ will automatically be activated,
if necessary. The box to enter the Boost factor will become available.
h) You also have the opportunity to enter a Description, not mandatory
i) Don’t forget to enter the results in the CDI

Note: For more information about setting up on a CDI Crystal , click Learn more about selecting
the boost factor and screen technology. For more information about setup on a CDI Spark,
contact Esko Support.

18. Choose the best Screening Dot (dot shape), based on what screening dot is printing the smoothest
gradients, improves overall printing quality and is showing the best stability throughout the print
run.
Check for:
• tonal jumps
• dot stability: random missing dots, deformed dots, …
• dot gain: what screen produces a dot gain closest to the printing standard (= less compensation
needed)
• color saturation of tints and solids
• …

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Note:
Depending the selected surface screening, not all screens will be available:
• MCWSI = only Crystal
• MG34 = Crystal, Circular, Round (Fogra), Elleptical, Double Circular
• Solid = Crystal, Circular, Round (Fogra), Elleptical, Double Circular
• MG45 = Circular, Round (Fogra), Elleptical, Double Circular

a) Compare the Crystal and Circular (classic) screen, on chart A

 

Note: If you don’t see a big difference between both screens (= no clear advantage for Crystal
screen), we advise to select Circular or another classic screen. Classic screens are more
tolerant for changes in plate making and printing.
b) If you choose to use the Crystal screen, skip to the next step. If you did not select Crystal
Screen:
1. If your surface screening is MG34 or MG35, compare the Circular (C), Round Fogra (R),
Elleptical (E), Double Circular (F), on chart B
 

 
2. If your surface screening is solid, compare Circular (C), Round Fogra (R), Elleptical (E), Double
Circular (F), on chart B
 

 
c) Check on the other copies you selected from your print run, if your selection shows similar
results, without issues!
d) Select the Screening Dot from the pull-down menu in step 2: Crystal, Circular, Round (Fogra),
Elleptical, Double Circular
19. Click Next in the lower right corner
20.Click Finish in the lower right corner
The selected Pixel Boost, Surface Screening, Solid Density, Screening Dot and description are now
shown on the Plate and Press Calibration page.

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Note: It is possible to edit the Plate and Press Calibration setup: see Change Plate Making and Press
Calibration Settings on page 82

Copy the calibration from another Printing Condition

1. To start the wizard, click Click here to start calibrating your plate making and press.
2. Select Copy the calibration from another printing condition
3. Click Next, in the lower right corner.
4. Select from which printing condition you wish to copy the parameters from.
a) click Select
b) Select a Printing Condition from the list

Note:
• By default, you can only select printing conditions using the same application (labels,
flexibles, …). To be able to select any printing condition from the list, Click Allow printing
conditions with a different application.

•
It is also possible to select an unfinished printing condition ( ), but only if the configuration
step Plate and Press Calibration is completed.

c) Click Select
5. A preview of the selected printing condition parameters are shown: Pixel Boost, Surface Screening,
Solid Density, Screening Dot and description are shown.
6. You have the opportunity to enter a Description, not mandatory.
7. Set the toggle Copy all hardware settings
If checked (default), not only the plate and press calibration settings will be copied from the
selected printing condition, but also all other available settings (plate making, press, printing
standard, …), except:
• the settings specified when creating the printing condition: inkset, substrate and application

• the settings from the configuration step Screens and Curves

8. Click Finish in the lower right corner
The selected Pixel Boost, Surface Screening, Solid Density, Screening Dot and description are now
shown on the Plate and Press Calibration page.

Note: It is possible to edit the Plate and Press Calibration setup: see Change Plate Making and Press
Calibration Settings on page 82

Define the plate screening settings manually

1. To start the wizard, click Click here to start calibrating your plate making and press.
2. Select Define the plate screening settings manually
3. Click Next in the lower right corner.
4. Select the Surface Screening from the pull-down menu in step 1: MCWSI, MG34, Solid or MG45

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5. Enter the Solid Density and select the Density standard you use on your measurement device (ANSI
A, DIN, …), not mandatory.
6. Select the Screening Dot from the pull-down menu in step 2: Crystal, Circular, Round (Fogra),
Elliptical, Double Circular

Note:
Depending the selected surface screening, not all screens will be available:
• MCWSI = only Crystal
• MG34 = Crystal, Circular, Round (Fogra), Elliptical, Double Circular
• Solid = Crystal, Circular, Round (Fogra), Elliptical, Double Circular
• MG45 = Circular, Round (Fogra), Elliptical, Double Circular

7. Enter the Boost Factor (Pixel Boost value) in step 3

Note: When you select the Surface Screening, ‘Use pixel boost’ will automatically be activated, if
necessary. The box to enter the Boost factor will become available.

8. You also have the opportunity to enter a Description, not mandatory.

9. Don’t forget to enter the results in the CDI

Note:
For more information about setting up on a CDI Crystal , click Learn more about selecting the boost
factor and screen technology.
For more information about setup on a CDI Spark, contact Esko Support.

10. Click Finish in the lower right corner

The selected Pixel Boost, Surface Screening, Solid Density, Screening Dot and description are now
shown on the Plate and Press Calibration page.

Note: It is possible to edit the Plate and Press Calibration setup: see Change Plate Making and Press
Calibration Settings on page 82

White
The goal of this configuration step is to improve the evenness of the ink film and the opacity for solid
white, by applying a surface screening.
There are different types of surface screening and depending the printing conditions, some will give
better results than others. By printing a test chart on press, you will be able to select the most optimal
surface screening for your printing condition.
This step is not mandatory and becomes available when the step Plate and Press Calibration is
completed.

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Note:
• As this configuration step is optional, the indicator will always be green , with or without
performing the White calibration.

• The White calibration is only available when you have license for an XPS exposer. The screen
technology for white ink (very fine surface screening pattern) requires the very consistent exposing
of a LED UV system (= XPS).
• We recommend to only use the White calibration for solvent inks, as other inks are not tested yet.

1. To start the wizard, click Click here to choose the screen for white.
2. Create the white chart
a) click Save Chart…
b) specify the folder where you want to save, click Select Folder
A file named PCW_White.LEN is created in the selected folder
Example of the white chart:
 

 
• This wizard always creates the same chart, independently of the parameters in the previous
steps. It is possible to re-use the same PCW_White.LEN file for other White calibrations.

• The chart will always be saved as a LEN file, no other formats possible.
• You can edit the LEN file in an Esko editor, to adapt for your production (plate size, bearer
bars, …). However, it is important that you don’t change any of the technical elements related
to the white screening.
3. Make a plate according to your company's Standard Operating Procedures using this LEN test
chart.

Note: It is not necessary to adjust the Pixel boost for the white, use the value from the process
colors.

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4. Make a Print using this plate, according to the printing condition and your company's Standard
Operating Procedures.
5. Click Next in the lower right corner.
6. Select the ink that you will use for white in your production files.
a) In step 1, click Select
b) In the top part of the dialog, select the ink book that contains your white
c) Select the ink in the list below
d) Click Select

Note: Typically, White from the Ink Book ClassicColors is used

It is possible to use any ink (the name does not need to contain white) from any ink book, as long
as the production files contain an ink using the exact same name and ink book as you select
here.
You can also use the remapping functionality in Automation Engine for this.
To create a new ink, see the chapter Adding an Ink to in Ink Book in the Color Pilot user guide:
https://www.esko.com/en/support/product?id=Color%20Pilot

Note: Click to remove the ink, or repeat the selection procedure

7. Evaluate the printed chart

a) Check if the overall quality of the printed result matches your current daily production.
b) The patch in the center (A) is a pure solid, without surface screening. The printed result of this
patch should be very similar to your current daily production.
c) The pure solid patch (A) is surrounded by 8 patches, each with a different surface screening
and labeled from B to I. Each patch is also horizontally divided in two sections with different
orientation of the MicroCells. In order to verify if the orientation will influence the quality of the
white.
Zoom on center of a patch:

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Choose the patch that shows the best printed result, by considering:
• What patch has the best opacity and evenness of the ink film?
• What patch doesn’t show a difference between the upper and lower part?

Note: It is possible that the pure solid (A) is showing the best result.

Note: For more information, click Learn more about choosing surface screening for white.

8. In Step 2, select the patch from the pull-down menu: A (Solid) to I

9. You also have the opportunity to enter a Description, not mandatory.
10. Click Finish in the lower right corner
• In case you selected B to I, a screen will be created with the name CRYSTAL WHITE X (where X
stands for the letter you selected: B to I).
• In case you selected A (Solid), no screen will be generated.
The selected ink, the calculated screen (or A (Solid)) and description are now shown on the White page.

Note: It is possible to edit the White setup: see Edit White on page 81

Substrate
Define the substrate you are using for your printing condition.
1. Select your Substrate Type:
• Acrylic: a substrate made of acrylate, polyacrylate or methyl methacrylate components, sold for
example under the Perspex, Plexiglas, Lucite or Acrylite trade names
• PE: a polyethylene, polyester, PET, PETG or HPDE substrate, sold for example under the Mylar,
Melinex, Hostaphan or BoPET trade names
• Spun PE: spun and bonded polyethylene, sold for example under the Tyvek trade name
• PP: a polypropylene, PVC or vinyl substrate
• PS: polystyrene
• Paper

Note: Substrate type is already filled in from the New Printing Condition dialog, but can still be
changed. See Creating a Printing Condition for Flexibles or Labels on page 26

2. Select your substrate's Opacity:

• Transparent
• White Underprint: where a white ink is printed under the other inks

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• White Overprint: where a white ink is printed on top of the other inks, for example for reverse
printing
• Opaque
3. Enter your substrate's Thickness in microns or mil, not mandatory.

Note: To change the units, see Preferred Units on page 19

4. Add a more detailed Description of your substrate. Not mandatory, but highly recommended to add
all data that identifies the substrate.

Ink Set and Printing Standard

Define what standard inks you are using on press and what targets you want to match the printing
result.
1. Select the ink set you are printing with.
This can be CMYK or an expanded gamut printing ink set (for example CMYK Orange Green Violet),
where the expanded gamut inks are part of the ClassicColors ink book.
For more information about expanded gamut printing, please see Equinox and Expanded Gamut
Printing in the Color Pilot documentation.

Note:
• Ink set type is already filled in from the New Printing Condition dialog, but can still be changed.
See Creating a Printing Condition for Flexibles or Labels on page 26

• Compared to the previous versions of the Print Control Wizard software, it is not possible
anymore to only use 1 ink. The minimum is CMYK.

2. Select the Printing Standard you want to match.

The Printing Standard contains the target data that will be used in the configuration step Screens
and Curves on page 47.
To know what standard to select, click What is a Printing Standard.
3. In Details you see an overview of the inks from the selected ink set.
Per ink you get more information about the target data of the standard you selected:
• The desired curve
• The desired density or tone of a 50%
• Target LabCh values for the solid inks

Plate Making
Specify in this configuration step what Flexo plates will be used and the way the plates are made
(image, expose, develop).
1. Select your Imager Type:
• CDI Crystal: the new generation of Esko imager, using the Crystal technology
• CDI Spark: an older generation of Esko imager

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For more information about Esko's different CDI models: https://www.esko.com/en/products/

digital-flexo-platemaking/cdi-spark/models
2. Select your Optics:
• For CDI Spark: Optics15, Optics25, Optics40, Optics80 or Optics80 V2

• For CDI Crystal: Optics40 V2 or Optics80 V2

Tip: If you don't know your CDI's optics technology, you can find it in the tables below (it is linked to
its maximum imaging speed).

Table: CDI Spark (Models 2530, 4835, 4260 and 5080)

Maximum Imaging Speed Optics Technology

1.5 m²/hr Optics 15

2.5 m²/hr Optics 25

4 m²/hr Optics 40

8 m²/hr Optics 80 or Optics 80 v2 (depending on the

model)

Table: CDI Crystal (Models 4835 and 5080)

Maximum Imaging Speed Optics Technology

4 m²/hr Optics 40 v2

8 m²/hr Optics 80 v2

3. Resolution:
The resolution that is used to image the plates on CDI, is fixed at 4000ppi. The screen technologies
in the Print Control Wizard (Pixel+, FM in highlights, …) require this resolution.
4. Select your Exposure Type:
• Inline-UV: Esko device that exposes inline the front of the plate directly after imaging,
• XPS Crystal: Esko device that simultaneously exposes the front and back of the plate, using UV
LEDs.
• Bank: non-Esko exposure device, can be an analog or digital device.

Note: To be able to guarantee a minimum quality, you can only select XPS for labels.

5. In Description, you can add information about your exposure devices, for example exposing times,
what device (if you own several exposing devices of the same type) ...
You can also add all other information that could not be specified in the default fields, information
that is important to identify how the plates are created.
6. Select your Plate Type.

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A wide range of plate types from different manufacturers is available. All plates in the list are tested
and approved by Esko, to be able to guarantee a minimum quality.
In the future more plate types could be added. Contact Esko support if your plate type is not in the
list.
Some plate types are listed twice, each with a different developer. Make the selection of your
developer type from this list.
7. Select your plate's Thickness, not mandatory
Depending the plate type you selected, you will have a fixed list of plate thicknesses. Only plate
thicknesses that are tested and approved by Esko will be available.
In the future more thicknesses could be added. Contact Esko support if your thickness is not in the
list.
8. Enter your Relief Depth, not mandatory
This is the depth of the dots on your plate (or the difference in height between the printing surface
and the floor of the plate).
You can calculate your plate relief depth (in red below) by measuring your plate's thickness (in blue)
and subtracting the plate floor's thickness (in green).
 

Note: To change the units, see Preferred Units on page 19

9. Developer: The type of developer is automatically defined when you select the plate type. It can be:
• Solvent
• Thermal
• Water
For some plate types we support more than 1 developer type.
Select your developer type in Plate Type.

Press Settings
Adding information about your press setup is not mandatory, but highly advised.
For every setup it is important to gather as much information as possible, to better understand at a
later time the conditions of the setup.

Note: As this configuration step is optional, the indicator will always be green

1. Enter the manufacturer name of your press (Press Brand).

2. Select your Press Type. It can be either:

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• Central Impression press: containing a single large-diameter common impression cylinder that
supports the substrate as it enters in contact with a series of adjacent plate cylinders.
• Stack Press: in which the substrate passes through multiple color stations which are aligned in
one or two vertical stacks).
• In-line Press: in which the substrate passes through multiple color stations which are aligned in
a straight horizontal line).
3. Select your Press Size
It is not possible to select a Cylinder Width, just the category Wide Web or Narrow Web.
4. Enter your press' Printing Speed in meters or feet per minute

Note: To change the units, see Preferred Units on page 19

5. In Press Inks you see an overview of the inks in your printing condition, setup in Ink Set and Printing
Standard and White.

Note: For white, the name of the ink you selected as white will be shown in the list.

Per ink you can add extra information about the ink, anilox and tape you will use on press:
a) Select the ink and click the Modify button, or double-click the ink
b) Specify the Ink Properties:
1. Enter the manufacturer of the ink (Brand)
2. Select the Type: Solvent, Water-based or UV curable
3. Enter the Viscosity in seconds
You can measure an ink's viscosity using an eux cup. The viscosity is the number of seconds
it needs to flow through the hole at the bottom of the cup until the cup is completely empty
(very viscous inks need longer). Some newer press models can measure this automatically
(electronically).

Note: The ink's viscosity affects how well it transfers onto your substrate, and can change
depending on ambient temperature and time (for example when the solvent in a solvent based
ink starts evaporating).
c) Specify the Anilox Properties
1. Enter the manufacturer of the anilox (Brand)
2. Enter the Type
3. Enter the anilox' Line Screen in lines per inch (this is the number of cells per linear inch).
A higher line screen is used for finer detail, while a lower one will transfer a heavier layer of
ink.
4. Enter the Angle of engraving (relative to the anilox axis) in degrees. This is typically 30°, 45°
or 60°.
5. Enter the anilox' Cell Volume (the ink capacity of each engraved cell) in billion cubic microns
(BCM).

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Note:
The cell volume of an anilox roll can change over time, due to wear, damage and
"plugging" (dried ink residues at the bottom of the cells). Plugging can happen when Solvent
or Water-based ink is not cleaned immediately after using the anilox and dries in (UV curable
ink will not dry on its own).

d) Specify the Tape Properties by entering the manufacturer of the tape (Brand)

Note: We recommend to also add the tape hardness in the same field.
e) If all your inks have the same properties, you can select Apply properties to all inks. This option
is enabled when no parameters have been set for any inks.
f) Click OK
All parameters per ink, are visible in the overview table.

Note: At any time, you can add, remove or edit data per ink.

Tip: First, add all data that most inks have in common, by using Apply properties to all inks. Then
edit the inks individually.

Screens and Curves

The final configuration step will generate the dot gain compensation curves and finish the setup
of your custom screen, by choosing the highlights ("mindot", or minimum dot) that are best for your
production.
To complete this configuration step, you have 2 options:
1. Measure charts to determine screens and adjustment curves on page 47 (recommended)
Select this option if you will print and measure charts. The wizard will guide you step by step.

Note:
Dot gain and highlights are very specific for a certain press-ink-substrate combination. Even if your
printing condition is very similar (for example same inks and substrate, but different press), we
highly recommend to print and measure the charts.
If the results are very similar to another printing condition, you can still decide to use the same
settings for both printing conditions.

2. Manually select screens and use default adjustment curves on page 67

Select this option if you know what settings to select for the highlights in your screen.
The software will select default dot gain compensation curves for all inks.

Note: It is possible to edit the curves later: see Update Curves on page 80

Measure charts to determine screens and adjustment curves

The screens and curves wizard consist of 5 steps, displayed in this way:

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Note:
When you Quit to Continue Later, the completed steps will be colored. The step where you will
continue from, is also colored and the text is darkened (Measure in the example below):
 

 
To continue the configuration, click Click here to continue making your screens and curves.

1. To start the wizard, click Click here to start making your screens and curves.
2. Select the Screen Ruling used in your production.
A fixed list of rulings is available from 100lpi to 250lpi. If your ruling is not in the list, choose the
closest available ruling.
If you are using several rulings, you can add additional rulings after you finished the printing
condition. See Add Ruling on page 71
3. Select the Angle Set used in your production.
From the pull-down menu, you have the same 3 options that are available in the Imaging Engine
tickets: Offset, Flexo-7.5, Flexo+7.5
Below the Angle Set selection, you find a list of all inks used in your Printing condition. You defined
this in Ink Set and Printing Standard on page 43

Note: When you have completed the setup for White, the ink you selected as white will also be
visible in the list. See White on page 39

The angles, defined by the Angle Set, are shown next to each ink.
It is possible to change the angle of an ink:
a) Click the angle
b) Select another angle from the list
c) The Angle Set will be set to <Custom>

Note: Some angles are bigger then 90°, this is due to the screening technology used in the Print
Control Wizard. The corresponding value in ‘the 90° zone’ is mentioned between brackets, make
your selection based on this value.

4. Select Measure charts to determine screens and adjustment curves (recommended)

5. Click Next in the lower right corner to continue to creating and printing the test chart. See Creating
and printing the test chart on page 49

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Creating and printing the test chart

1. Create the test chart:
a) A preview of the default layout is shown for labels (left) and for flexibles (right)
 

Note: The illustrations of the charts in this manual are just 1 example of the many possible
versions. Your chart could look slightly different from the sample in this user guide !
b) Add chart options to customize the layout

Note: All changes will be visualized in the preview.

• Mirror Image: to be used for reverse printing

This option is on by default when using White Overprint in Substrate on page 42.

• Add default bearer bars, slur marks and registration marks:

This option is always on by default.

• Add a custom element:

If you want to add an image or technical element to the chart, to quality control the print.
1. Click Browse
2. Browse to the location of the file
3. Click Open

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Note:
• The element needs to be a .ct file (Esko native image file format). Use an Esko editor to
create .ct files from your element.
• You can only add 1 element. If you want to add several elements, first group them in an
Esko editor.

Note:
A fixed area of 10cm x 49,6cm for flexibles and 10cm x 32,6cm for labels will be added at the
bottom of the layout. If the element is smaller, the remaining space will be kept on the layout
(and will be on the plate).
To avoid this unused space, it is advised that the dimensions of the file are close to the
dimensions of the fixed area.
It is also possible to scale the element, by using the option below.

• Proportionally enlarge the custom element to fit the chart width or height

The custom element will be scaled proportionally, until either the width or the height fits the
fixed area (10cm x 49,6cm for flexibles and 10cm x 32,6cm for labels)

• Split into multiple charts

If the layout is too big for your press, you can use this option.
The layout will automatically be split in several smaller parts. All elements that need to be
printed together will be placed on the same layout.

Note: You can see the dimensions of the layout, on top left of the preview.
c) Click Save Chart
d) Specify the folder where you want to save, click Select Folder
e) Specify a File name
f) Select the File Type you want to save: LEN or Tiff

Note: Save as Tiff files if the chart options are not sucient to adapt for your production
(bearer bars, …), because Tiff files are more easy to edit. However, it is important that you don’t
change any of the technical elements! In all other cases, save as LEN files and use them directly
on the CDI.
g) Click Save
For each ink in your printing condition, a file will be created in the selected folder. For example
if your inkset is CMYK and you completed the White setup, you will get 5 files: File name_C, File
name_M, File name_Y, File name_K, File name_White

Note: It could take several minutes to create the file.

Note: The created chart is based on numerous parameters from the previous steps (application,
dot shape, surface screening, …). Always create a new chart, to assure that you have the correct
elements in your chart for your printing condition.

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2. Image the plates on CDI according to your company's Standard Operating Procedures, AND using
the settings specified in the previous steps.
3. Make a Print using these plates, according to the settings you entered in the printing condition and
your company's Standard Operating Procedures.

Note:
To have an accurate and reliable screens and curves creation, it is important that the
measurements are an average of a complete print run.
We therefore recommend:
• after reaching printing conditions (= first ok sheet), print 50 to 100 meters (or more if this better
reflects your production)
• starting from the first ok sheet, select min 3 copies (advise = 5) that represent the complete
printrun: begin – middle – end

4. Click Next in the lower right corner to continue to checking the printed chart. See Checking the
printed chart on page 51

Checking the printed chart

1. Check Slur and Impression marks on the print
 

 
a) Check your prints
• use a magnifying glass
• ALL marks (= all inks) on the print should be ok

• verify all copies. If 1 or more copies are not ok, they should be replaced by a copy from that
same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with the press
operator and reprint.
To know how to evaluate the marks, click Learn more about evaluating this area
b) Select the Check Slur Marks area in the preview image of the chart
 

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c)
Accept or Reject
2. Check Dot Fail on the print.
 

 
a) Check your prints
•use a magnifying glass
•check the center and lower row
•the smallest number where all dots are in position gives the resulting value.
•verify all copies. If 1 or more copies are not ok, they should be replaced by a copy from that
same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with the press
operator and reprint.
• compare to the value that was found as good quality during installation of the CDI, same
value as used during Plate and Press Calibration on page 28
b) Select the Check Dot Fail area in the preview image of the chart
 

 
c)
Accept if the result matches the reference, or Reject if the result doesn't match.
3. Check Registration marks on the print
 

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a) Check your prints
• use a magnifying glass
• ALL marks on the print should be ok

• verify all copies. If 1 or more copies are not ok, they should be replaced by a copy from that
same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with the press
operator and reprint.
• To know how to evaluate the marks, click Learn more about evaluating this area
b) Select the Check Registration Marks area in the preview image of the chart.
 

 
c)
Accept or Reject
4. Click Next in the lower right corner
When your print quality is ok, you accepted all 3 areas, and you will get an approval on this page. It is
possible to continue to the next step.
 

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Note:
If you rejected 1 or more checks, you cannot continue to the next step. When you click Next in the
lower right corner, you will be re-directed to the previous page.
 

Troubleshoot with the press operator and reprint if necessary. When the new tests are positive, you
can change the state from Reject to Accept for that area.
5. Click Next in the lower right corner to continue to measuring the charts. See Measuring the chart on
page 54

Measuring the chart

1. Measure the Mindot Chart
You can see the mindot chart for Labels (left) and for Flexibles (right) below.
 

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This will be used to determine the screen for the highlights.
The magenta printed part will be used for CMY, the black printed part for K. If your selected ink set
contains 1 or more extra inks (OGV), the first ink will be added to the chart, to be used for OGV.
For example if the ink set is CMYKOG, orange will be added to the chart.
a) Cut out the chart from your first copy.
b) The chart can be read in patch or scan mode by an X-Rite i1 Pro or X-Rite i1iO. No other
measurement devices are supported.
To measure with the i1 Pro, it is advised to cut off the text before each row.
c)
With the cogwheel ( ) on the bottom right, you can stop, calibrate and reconnect your
measurement device, change the measurement mode and the measurement condition.
See the chapter Using a Spectrophotometer in the Color Pilot user guide: https://
www.esko.com/en/support/product?id=Color%20Pilot.
d) To know how to measure the chart with your measurement device, follow the instructions on the

bottom left above the icons .

The preview will visualize the instructions and the measurement progress.
2. Click Next in the lower right corner.
3. Check the Measurement results.
a) Check the preview: the upper and lower part of the patches should approximately have the same
color.

Note:
The comparison of measurements (upper part) and the standard (lower part) is a rough
approximation. Only look for clear differences:
• completely different color: for example wrong row measured, chart upside down
• the same color, but a very big difference in lightness: for example not printed correctly, issue
with the measurement device.

b)
Accept or Reject
When your measurement is ok, it is possible to continue to the next step.
If you rejected the measurement result, you will be guided to measure again, following this same
procedure.
This could be the same chart (wrong row, chart upside down) or a different chart from the print run.
4. Click Next in the lower right corner.
5. Measure the Tone Value Chart for Labels (left) or Flexibles (right).
 

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• This will be used to create the dot gain compensation curves.

• The chart will contain all inks from your selected ink set.
For example if the ink set is CMYKOGV, the chart will contain CMYKOGV patches.

• Cut out the chart from the same copy as your mindot chart in the previous steps.
• The chart can be read in patch or scan mode by an X-Rite i1 Pro or X-Rite i1iO. No other
measurement devices are supported.

•
With the cogwheel ( ) on the bottom right, you can stop, calibrate and reconnect your
measurement device, change the measurement mode and the measurement condition.
See the chapter Using a Spectrophotometer in the Color Pilot user guide: https://
www.esko.com/en/support/product?id=Color%20Pilot.

• To know how to measure the chart with your measurement device, follow the instructions on the

bottom left, above the icons .

The preview will visualize the instructions and the measurement progress.
6. Click Next in the lower right corner.
7. Check the measurements results.
a) Check the preview, the upper and lower part of the patches should approximately have the same
color.
After the first measurement you can compare your measurement to the standard. After the
measurement of your 2nd, 3rd… copy, you can also compare to the average and to the other
measurements.
Select what you want to compare with, from the pull-down menu, on top of the preview.

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Note:
• In this step we mainly want to detect if the charts were measured correct (not upside down,
mirrored…)
If the color in the patch is the same, but there is a big difference in lightness, this is probably
not an issue. The dot gain compensation curve created from these measurements will
correct for this.

• Comparing charts among each other could be useful, to detect if some charts are printed
very different. That chart could be an exception and we don’t want to include this in our
average.

b) Check the solid info, to the right of the preview.

1. Density: for each ink, the measured density should be within tolerance of the desired density.
Use the same tolerance as your company uses on press (typically + or - 0,05).
Select the Density standard you use on your measurement device (ANSI A, DIN, …), from the
pull-down menu below the Solid Info.

Note:
The desired density is derived from the printing standard you selected in Ink Set and Printing
Standard
We don't show desired density for CMYK inks for standards that use an ICC profile as a
standard profile. This is because density calculation requires spectral data, which is not
available in ICC profiles.

2. Color difference (∆E): for each ink, the ∆E should be within tolerance of the printing standard
you selected in Ink Set and Printing Standard. See Ink Set and Printing Standard on page
43.
Select the ∆E Formula that is requested by the printing standard, from the pull-down menu
below the Solid Info.

Note: Select an ink if you want to see the LabCh details, below the Solid Info window.

Note: We don't show desired density, Lab and ΔE for the OGV inks. There are no standards for
these inks, so there's nothing to match.
c)
Accept or Reject
When your measurement is ok, it is possible to continue to the next step.

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Note:
If you rejected the measurement result, you will be guided to measure again.
You will also have to measure and check the results of the mindot chart again. As both charts are
linked to each other.
Reason:
• if you detect a printing issue on the Tonal Value chart, then the complete copy will most likely not
be representative. Your mindot measurement will be less reliable.
• To avoid mixing charts of different copies.

8. Click Next in the lower right corner.

9. Select Measure another sample if needed.
To have an accurate and reliable screens and curves creation, it is important that the
measurements are an average of a complete print run. Measure minimum 3 charts of good print
quality (we advise to use 5).
a) Click Next in the lower right corner.
b) You will be guided to measure again. Following this same procedure from the top.

Note: The wizard will indicate how many charts you already measured: sample 1, sample 2…

10. If you measured enough charts of good quality, you can select Stop measuring and inspect the
resulting screens.
11. Click Next in the lower right corner to continue. See Overview of the selected screen and highlights
on page 58.

Overview of the selected screen and highlights

View at the top, an overview of the screen technology and highlights selected from the measurements.
One selection is made for CMY (based on magenta part in mindot chart), another for K and another for
OGV (if present, based on the part in mindot chart printed in the fifth separation).
You see per ink group (CMY, K and OGV) what is the selected:

Screen Technology:
1. The first part of the screen name is the screening dot (dot shape) you selected in Plate and Press
Calibration: Crystal, Crystal C or Crystal NP. See Plate and Press Calibration on page 28
2. The surface screening selected in Plate and Press Calibration will be mentioned after the screening
dot: MG34, MG45 or SOL (=solid). See Plate and Press Calibration on page 28
Exceptions for Crystal NP:
• the dotshape (R, C, F or E) will be mentioned after the surface screening, for example Crystal NP
MG34 R9
• SOL will not be mentioned if surface screening Solid is used, for example Crystal NP R6
Exceptions for Crystal and Crystal C:
• when MCWSI is selected, nothing will be mentioned in the name, for example Crystal 6 or Crystal
C12
• for Crystal C, the ‘C’ will be mentioned after the surface screening, for example Crystal MG34 C3

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3. The number at the end indicates the size (in pixels) of the minimum dot, used in the screen.

Note:
• For Crystal C and Crystal NP: it indicates the number of pixels that will form the printing dot
• For Crystal: it indicates the number of boosted pixels. As each pixel will be boosted (pixel+) on
the CDI, the size of the printing dot will be bigger than the amount of pixels.

4. If a support dot is selected, the support dot characteristics will be mentioned at the end of the
screen name, for example Crystal 4 S4R1
• The size of the support dot: S3 = 3 pixels

• The type of ruling used: R1 = single ruling, R2 = double ruling)

5. For more information, see:
• Types of Screens on page 14

• Learn more about inspecting highlights

Code
When the screen is created, a code needs be assigned to the screen. So the screen can be easily used,
communicated and traced back by Esko software and operators. Comparable to other Esko screens:
Circular dot = C; an HD screen = HDxx; …
This code is unique and will automatically be selected, based on ‘next available in the list’.
It is possible to change the code BEFORE creation:
1. Click Select, next to the code
2. Select a screen code from the list
3. Click OK

Note: If the screen already exists, because it was already created in another Printing Condition, the
code will be greyed out and labeled (already exists). It is not possible to change the code.

Minimum Dot on Plate

The size (diameter) of the selected minimum dot is mentioned in microns (µm).

Note: As boosted pixels on CDI gets bigger then ‘regular’ pixels, the diameter of 4 boosted pixels
(Crystal 4) will be bigger than the diameter of 12 regular pixels (Crystal C12 or Crystal NP C12).

FM dot population
The FM dot population indicates the amount of dots used to print the highlights.

1/1 means that all the dots are kept (the screen doesn't use FM
screening)

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1/2 means that half of the dots are kept (resulting in FM screening)

1/4 means that a quarter of the dots are kept (resulting in FM

screening)
A lower FM dot population gives lighter highlights, but may increase
graininess.

Transition point:
• If 1/1 (no FM): there is no transition point, the minimum dot will be the bump.
• If 1/2 or 1/4 (FM): the transition point, where the AM screen starts changing into an FM screen, will
be determined by the minimum dot.
If you see 1/4, it means that the screen gradually transitions from 1/1 (no FM) to 1/2, then to 1/4 in the
highlights, as you can see below.
 

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Lightest Tone Value

The lightest tone that can be printed, will be displayed.
The value is the result of the selected minimum dot and FM dot population. The combination that gives
in print a stable dot and the lightest highlight, will be automatically selected from the measurements

Continue to inspect the screen results

See Inspect the screen results on page 61

Inspect the screen results

1. Locate on your print sample, the highlight check areas.
In the example below, the CMY area is marked, for Labels (left) and for Flexibles (right)

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• Per available Ink Group (CMY, K and OGV) you will have a set of HIGHLIGHT CHECK’s. The set is the
same for each ink group.
• The number of HIGHLIGHT CHECK’s depends on the Screening Dot you selected in Plate and
Press Calibration (could be different number than the examples above).

• For every available screen technology there will be a HIGHLIGHT CHECK.

 

 
It shows the screens highlights (from 0 to 5%) for:
• different FM Dot Population: 1/1, 1/2 and 1/4

• different Minimum Dot (in pixels)

2. In the overview, select the Ink Group you want to inspect: CMY, Black or OGV

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You will see your selected highlight in the preview, the area will be marked with a blue rectangle.
 

 
3. Locate the same area on your print sample, and inspect it on a light booth using a magnifier
 

 
a) Skip the next step and continue with the inspection of the other ink groups, if the highlights
gradient fade smoothly (as in the gradient A)
b) Continue to the next step, if the highlights quality is not good enough and you encounter any of
the issues below:
• B: the screen prints too dark, giving a hard edge in the highlights
• C: there is tone reversal in the highlights
• D: the print is too grainy

Note:
Inspect the screen results on ALL print samples were you measured the charts! The selected
highlight should fade smoothly on all samples. If not, try to find a better highlight. To avoid that
you will see the same unstable print behavior in your daily production.

For more information, click Learn more about inspecting highlights.

4. Select a highlight that you consider better

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a) Inspect the neighboring highlight gradients (within the same or another FM Dot Population) to
try and find better quality highlights.
If you don't find any satisfactory highlights for your selected screen technology, inspect the
highlights of another screen technology (for example Crystal C instead of Crystal).
b) To select the better highlight, click the area in the preview.
• The blue rectangle will be placed in the new selected area.
• The selection from the measurements will be marked with a grey rectangle.
• The Ink Group will be marked with and the new settings will be applied.

Note:
If you found the better highlight in another screen technology, first select the screen
technology from the pull-down menu (on top of the preview).
Only screens that are related to the screening dot you selected in Plate and Press Calibration will
be available.

Note: Click Reset (top right of the preview), to remove your change.
c) Enable Show mindot strip with densities (on top of the preview), if you need additional
information to help you make your choice.
Next to the highlight check preview, the mindot strip of the selected Ink Group is displayed, with
the detailed result of your measurements.
 

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The patches on screen are arranged as in your print sample, by minimum dot size (horizontally)
and FM dot population (vertically).
For each patch, you can see the tone value produced by the screen in this patch, and the wizards'
evaluation:
• The patch with a green check is the one the wizard considers optimal: it prints in a stable
way and produces the lightest highlights of all the stable patches
• Patches with no specific markings also print in a stable way
• Patches with a red cross do not guarantee a stable print
• Hover on a specific patch, to see more information below the strip

Tip:
A stable print gives a smooth result without any clumping or missing dots.
 

Note: In the mindot preview, you can also select the better highlight. The Highlight preview will
be automatically adapted.

5. Inspect the screen result of another ink group, using the same procedure as the previous steps.
When all ink groups are inspected and the correct settings are applied, continue to the next step.
6. Click Next in the lower right corner
7. Select which separation from your printing condition will be used to set the default screen and
curve for your spot colors (= all separations that are not in the ink set).
The default is Black, but you can select any of the inks from the Printing Condition. Or <none>, if
your spot colors don’t need to use the screen and curve from your printing condition.
8. Click Finish
The screens and curves will be created (this could take some time) and the wizard will be closed.

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Note:
To better understand how the Print Control Wizard calculates the minimum gray value (H38
(min2.7%,h100000,s79)) of the curve, see the example below:
For Crystal C screen at a specific tone in the highlights, P+ dots are mixed with solid dots. Because
solid dots print larger, these solid dots need to be reduced. This is done with a reducing factor,
internally called as 'AM2WSI' parameter. This factor is around 5/8 = 0.625, so when the 'minimum' in
the PressSync curve is set to 2.7%, the real gray level in the LEN file will be: 2.7% x 0.625 = 1.69%.
When 1/1 population is selected in PCW, the required bump to have no FM is setting the 'minimum'
PressSync parameter equal to the transition point (point where AM goes to FM). Also here the
AM2WSI parameter is used.
Note also that in 20.0 a 'keep0%' is added to the curve and set to 0.39% Result is that the 1st 8-bit
CT tint (=0.39%) will have a gray value of : ‘minimum’ * ‘AM2WS’I
In previous version of Print Control Wizard (18.1.1), 'keep0%' was set to 0%, so the gray value of the
1st 8-bit tint was about 0.3% higher than ‘minimum’ * ‘AM2WSI’

All information about the selected screens, curves and measurement results are now shown on the
Screens and Curves page. See The Screen and Curves page on page 66

The Screen and Curves page

The Screens and Curves page shows all information about the selected screens, curves and
measurement results.
On top of the page, an overview of all inks in the printing condition are displayed.

Note:
Other is not shown when you didn’t select a separation for your spot colors in the last step before
finishing Screens and Curves.

For each ink, the following info is shown:

• Ink Book
• Printing Angle
• Screen name: screen code + screen technology
• Adjustement curve: the dotgain compensation curve for each ruling (see PressSync Curves on page
10)
At the bottom of the page, detailed information about the Tone Value measurements and the curves
are displayed.
• Curves, view of the measured and compensation curves
1. Select the tab Curves
2. Select the ruling from the pull-down menu

Note: If only 1 ruling is present in the printing condition, the ruling will be grayed out
3. Disable Show printing standard, if you don’t want to see the reference curve of the standard in
the Measured Curves graph (full line)
4. Select 1 or more inks from the overview, on top of the page.

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Note:
• If you didn’t select an ink, all inks will be displayed.
• Hold the shift key to select an extra ink

5. You will see the measured curve as a dotted line in the Measured Curves graph
6. You will see the dot gain compensation curve in the Adjustment curves graph
• Gamut, basic view of your color gamut (only ab at 50%)
1. Select the tab Gamut
2. Select the ruling from the pull-down menu

Note: If only 1 ruling is present in the printing condition, the ruling will be grayed out
3. Disable Show printing standard, if you don’t want to see the gamut of the standard in the graph
(white line)
4. Select an ink from the overview, on top of the page, to highlight the ink in the graph
• Gray Balance, view of the measured gray balance
1. Select the tab Gray Balance
2. Select the ruling from the pull-down menu

Note: If only 1 ruling is present in the printing condition, the ruling will be grayed out
3. Uncheck the thick box CMY a or CMY b, if you only want to see 1 curve in the graph
• Solid densities, spectral and density data of the solids, compared to the selected standard of the
Printing condition
1. Select the tab Solid densities
2. Select the ∆E formula, used for the ∆E calculation between your measurement and the standard
From this page you can also:
• Define new screens and curves: see Change Screens and Curves on page 82
• Update the current curves: see Update Curves on page 80
• Add an extra ruling: see Add Ruling on page 71
• Open the Curve strategy (Curve set) in Curve Pilot: click xxxxxx.icpro, on the right of the page (see
Curve Strategies on page 12)
• View the measurements of the mindot and tone value charts:
a) Click View Measurements
b) Select the chart you want to view, from the pull-down menu top left: Mindot or Tone Value
c) Select 1 of the samples you measured, from the pull-down menu top left: Sample0, sample1, …
d) In the preview, hoover over a patch or click on a patch
e) Check the CMYK and LabCh values of the patch, below the preview
f) Click Done, to leave the measurement view

Manually select screens and use default adjustment curves

1. Click Click here to start making your screens and curves
2. 2. Select the Screen Ruling used in your production
A fixed list of rulings is available from 100lpi to 250lpi. If your ruling is not in the list, choose the
closest available ruling.

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If you are using several rulings, you can add additional rulings after you finished the printing
condition. See Add Ruling on page 71.
3. Select the Angle Set used in your production
From the pull-down menu, you have the same 3 options that are available in the Imaging Engine
tickets: Offset, Flexo-7.5, Flexo+7.5
Below the Angle Set selection, you find a list of all inks used in your Printing condition. You defined
this in Ink Set and Printing Standard.

Note: When you have completed the setup for White, the ink you selected as white will also be
visible in the list. The angles, defined by the Angle Set, are shown next to each ink.

It is possible to change the angle of an ink:

a) click the angle
b) select another angle from the list
the Angle Set will be set to <Custom>

Note: Some angles are bigger then 90°, this is due to the screening technology used in the Print
Control Wizard. The corresponding value in ‘the 90° zone’ is mentioned between brackets, make
your selection based on this value.

4. Select Manually select screens and use default adjustment curves

5. Click Next in the lower right corner
At the top, an overview of the selected screen technology and highlights is displayed. For more
information, see Overview of the selected screen and highlights on page 58
6. Select the Screen parameters
a) In the overview, select the Ink Group: CMY, Black or OGV
b) Select the Screen Technology
Only screens that are related to the screening dot you selected in Plate and Press Calibration,
will be available. See Plate and Press Calibration on page 28
c) Select the Mindot
The available mindots in the list are related to the selected screen technology
d) Select the FM Dot Population: 1/1, 1/2 or 1/4
e) Repeat the steps for the other ink groups
When all ink groups are inspected and the correct settings are applied, continue to the next
step.
7. Click Next in the lower right corner
8. Select which separation from your printing condition will be used, to set the default screen and
curve for your spot colors (= all separations that are not in the ink set).
The default is Black, but you can select any of the inks from the Printing Condition. Or <none>, if
your spot colors don’t need to use the screen and curve from your printing condition.
9. Click Finish
The screens and curves will be created (this could take some time) and the wizard will be closed.

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Note:
When you manually setup Screens and Curves, the selected curves will always be F40 for Flexibles
and E50 for Labels. Only the flexible curve options (value shown between brackets) will be
calculated, based on the selected screening parameters. See PressSync Curves on page 10

All information about the selected screens, curves and measurement results are now shown on the
Screens and Curves page. See The Screen and Curves page on page 66

6.1.2. Reviewing the Printing Condition

After finishing the last configuration step Screens and Curves, the Printing Condition is ready to be
used. This is indicated in the banner on top, and by a green check mark on the right.

The configuration steps no longer have an indicator ( , , ) next to their name.

1. Navigate between the configuration steps and view the selected parameters.
2. Check if all parameters are correct. See Editing Flexibles or Labels Printing Conditions on page 71
if you want to correct some settings.

Note: Be careful if you want to edit mandatory parameters ( ), some configuration steps will be
reset and you will have to repeat these steps. A warning will be shown.

3. Save a report, if needed. See Saving a Report on page 69.

4. Click Close to return to the Printing Conditions Explorer. See Printing Conditions Explorer on page
21.

6.2. Saving a Report

It is possible to save a report (PDF) for a finished printing condition.
You can customize the report, so it only contains the data that you want to share and it holds your logo.
1. Open the Save Report dialog
• In the Printing Conditions library, select the printing condition and click the Save Report button

in the bottom toolbar

• In the Printing Conditions library, right-click the printing condition and select Save Report...
• Open the printing condition and click the Save Report... button in the lower right corner.
2. Specify the folder where you want to save
a) Click Browse
b) select the folder
c) click Save
3. Specify a File name. The default name will be: name of printing condition_Report.pdf
4. Select a different Banner, for example if you want to add your logo on the report.
a) Click Browse

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b) Browse to the location and select the file

c) click Open
Your banner will be previewed. Supported file formats are .jpeg, .png, .gif and .bmp. The size of
the banner area is 20cm by 2,7cm. Larger or smaller images will be resized.
Click Reset if you want to return to the default Esko banner.
5. Enter a Description if you want to add extra information to the report
6. Select what information you want to include, by enabling the corresponding options.

Hardware settings
Parameters from Plate and Press calibration, Substrate, Ink Set and Printing Standard, Plate
Making and Press will be added to the report.

Note: Parameters that are not filled in, will not be visible on the report.

Screens and adjustments curves

A table showing an overview of all inks in the printing condition.
For each ink, the Name, Ink Book, Angle, Screen Name and Adjustment curve is specified.

Note: If there are multiple rulings for the selected printing condition, a separate table is added for
each ruling.

Curves and gray balance preview:

For each ink and ruling in the printing condition (except Other and White), 2 graphs are added:
Measured Curve and Adjustment Curve.
The Graphs are grouped by ruling.
An extra Graph per ruling is added for the Gray Balance measurements.
Gamut outline:
Basic view of the color gamut (only ab at 50%) per ruling
Comparison of gamut outline with printing standard:
Will add the reference gamut of the selected printing standard (white outline) to the Gamut outline
view.

Note: This check box is only available when the Gamut Online checkbox is selected.

Solid densities:
A table showing per ink, the spectral and density measurement data of the solids.

Note: If there are multiple rulings for the selected printing condition, a separate table is added for
each ruling.

Comparison of solid densities with printing standard:

The reference data of the selected printing standard will be added to the Solid densities table and
compared to the measured data.

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Note:
This check box is only available when the Solid densities check box is selected.

Note:
• Most of the information is shown as on the page of the printing condition step.
• Some check boxes will not be available, if the information is not present in the Printing
condition. For example if Screens and Curves were manually added (no measurements): Gamut
outline, Solid Densities and both Comparison check boxes will be greyed out.

7. Click Save
The report (.pdf) will be saved in the selected folder and will open automatically in the default
application of the Windows Operating System.

6.3. Editing Flexibles or Labels Printing Conditions

6.3.1. Add Ruling

When you created your printing condition for flexibles or labels, you typically selected the main ruling
used in your production. If you are also using other rulings for this printing condition, you can add them
one by one.
All rulings will use the same screening setting, only the curves will be different. A wizard will guide you
through the steps to print and measure a test chart.

Important: The chart is different from the chart used in Screens and Curves, it only contains the tone
value part. Don’t re-use the plates made for Screens and Curves!

Note:
When adding extra rulings, the user is restricted to the 2 rulings closest (1 lower, 1 higher) to the ruling
that was used during setup of the printing condition.
This is because when deviating too much from the original ruling, the screening parameters are no
longer valid.
When all available rulings have already been added to the printing condition, an error message is
shown.

At any point in the process you can stop working on your printing condition and continue later. Use the
buttons Close and Quit Now and Continue Later. Don’t forget to Save when asked.

In the Printing Conditions library, the printing condition will get the mark in front of the name.
When you are ready to continue, start the wizard. You will be asked to Resume or to Start a new
session. Click Resume to continue editing your printing condition.

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Note:
• You can continue to use the printing condition, when you didn’t finish editing.
• Only one unfinished session can be available per printing condition. You need to finish first the
current session if you want to add a new ruling or update curves. The new session will overwrite the
unfinished session.
• It is possible to remove an unfinished task, right-click on your printing condition and select Remove
Unfinished Task.

1. Start adding a new ruling:

• In the Printing Conditions library, select the printing condition and click the Add Ruling button

in the bottom toolbar

• In the Printing Conditions library, right-click the printing condition and select Add Ruling...
• Open the printing condition and click Add Ruling... in the center of the Screens and Curves
overview..
2. Select the Screen Ruling

Note: On top, you see an overview of the already selected screens and curves for every ink and
ruling.

3. Click Next in the lower right corner

4. Create the test chart:
a) A preview of the layout is shown
 

 
b) Add chart options to customize the layout

Note: All changes will be visualized in the preview.

• Mirror Image: to be used for reverse printing

This option is on by default when using White Overprint in Substrate on page 42.

• Add default bearer bars, slur marks and registration marks:

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This option is always on by default.

• Add a custom element:

If you want to add an image or technical element to the chart, to quality control the print.
1. Click Browse
2. Browse to the location of the file
3. Click Open

Note:
• The element needs to be a .ct file (Esko native image file format). Use an Esko editor to
create .ct files from your element.
• You can only add 1 element. If you want to add several elements, first group them in an
Esko editor.

Note:
A fixed area of 10cm x 49,6cm for flexibles and 10cm x 32,6cm for labels will be added at the
bottom of the layout. If the element is smaller, the remaining space will be kept on the layout
(and will be on the plate).
To avoid this unused space, it is advised that the dimensions of the file are close to the
dimensions of the fixed area.
It is also possible to scale the element, by using the option below.

• Proportionally enlarge the custom element to fit the chart width or height

The custom element will be scaled proportionally, until either the width or the height fits the
fixed area (10cm x 49,6cm for flexibles and 10cm x 32,6cm for labels)

• Split into multiple charts

If the layout is too big for your press, you can use this option.
The layout will automatically be split in several smaller parts. All elements that need to be
printed together will be placed on the same layout.

Note: You can see the dimensions of the layout, on top left of the preview.
c) Click Save Chart
d) Specify the folder where you want to save, click Select Folder
e) Specify a File name
f) Select the File Type you want to save: LEN or Tiff

Note: Save as Tiff files if the chart options are not sucient to adapt for your production
(bearer bars, …), because Tiff files are more easy to edit. However, it is important that you don’t
change any of the technical elements! In all other cases, save as LEN files and use them directly
on the CDI.
g) Click Save

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For each ink in your printing condition, a file will be created in the selected folder. For example
if your inkset is CMYK and you completed the White setup, you will get 5 files: File name_C, File
name_M, File name_Y, File name_K, File name_White

Note: It could take several minutes to create the file.

Note: The created chart is based on numerous parameters from the previous steps (application,
dot shape, surface screening, …). Always create a new chart, to assure that you have the correct
elements in your chart for your printing condition.

5. Image the plates on CDI according to your company's Standard Operating Procedures, AND using
the settings specified in the previous steps.
6. Make a Print using these plates, according to the settings you entered in the printing condition and
your company's Standard Operating Procedures.

Note:
To have an accurate and reliable curves creation, it is important that the measurements are an
average of a complete print run.
We therefore recommend:
• after reaching printing conditions (= first ok sheet), print 50 to 100 meters (or more if this better
reflects your production)
• starting from the first ok sheet, select min 3 copies (advise = 5) that represent the complete
printrun: begin – middle – end

7. Click Next in the lower right corner

8. Check Slur and Impression marks on the print
 

 
a) Check your prints
• use a magnifying glass
• ALL marks (= all inks) on the print should be ok

• verify all copies. If 1 or more copies are not ok, they should be replaced by a copy from that
same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with the press
operator and reprint.
To know how to evaluate the marks, click Learn more about evaluating this area
b) Select the Check Slur Marks area in the preview image of the chart
 

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c)
Accept or Reject
9. Check Gradient on the print
 

 
a) Check your prints
•The gradient for every ink on the print should be ok: Smoothness, highlights, solid, … You
could compare to your print, used during setup of screens and curves. This can be used to
decide between making a new printing condition or adding the ruling to the existing printing
condition.
• verify all copies. If 1 or more copies are not ok, they should be replaced by a copy from that
same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with the press
operator and reprint.
b) Select the Check Gradient area in the preview image of the chart
 

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c)
Accept or Reject
10. Check Registration marks on the print
 

 
a) Check your prints
• use a magnifying glass
• ALL marks on the print should be ok

• verify all copies. If 1 or more copies are not ok, they should be replaced by a copy from that
same strip (for example from around 30m). If only 1 copy is ok, troubleshoot with the press
operator and reprint.
• To know how to evaluate the marks, click Learn more about evaluating this area
b) Select the Check Registration Marks area in the preview image of the chart.
 

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c)
Accept or Reject
When your print quality is ok, you accepted all 3 areas, and it is possible to continue to the next
step.
 

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Note:
If you rejected 1 or more checks, you cannot continue to the next step.
 

 
Troubleshoot with the press operator and reprint if necessary. When the new tests are positive, you
can change the state from Reject to Accept for that area.

11. Click Next in the lower right corner

12. Measure the Tone Value Chart
 

 
• The chart will contain all inks from your selected ink set.
For example ink set is CMYKOGV: chart will contain CMYKOGV patches

• The chart can be read in patch or scan mode by an X-Rite i1 Pro or X-Rite i1iO. No other
measurement devices are supported.

•
With the cogwheel ( ) on the bottom right, you can stop, calibrate and reconnect your
measurement device, change the measurement mode and the measurement condition.
See the chapter Using a Spectrophotometer in the Color Pilot user guide: https://
www.esko.com/en/support/product?id=Color%20Pilot

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• To know how to measure the chart with your measurement device, follow the instructions on the

bottom left, above the icons

The preview will visualize the instructions and the measurement progress.
13. Click Next in the lower right corner.
14. Check the measurements results
a) Check the preview, the upper and lower part of the patches should approximately have the same
color.
After the first measurement you can compare your measurement to the standard. After the
measurement of your 2nd, 3th, … copy, you can also compare to the average and to the other
measurements.
Select what you want to compare with, from the pull-down menu, on top of the preview.

Note:
• In this step we mainly want to detect if the charts were measured correct (not upside down,
mirrored, …)
If the color in the patch is the same, but there is a big difference in lightness, this is probably
not an issue. The dot gain compensation curve created from these measurements will
correct for this.

• Comparing charts among each other could be usefull, to detect if some charts are printed
very different. That chart could be an exception and we don’t want to include this in our
average.

b) Check the solid info, to the right of the preview

1. Density: for each ink, the measured density should be within tolerance of the desired density
Use the same tolerance as your company uses on press (typically + or - 0,05)
Select the Density standard you use on your measurement device (ANSI A, DIN, …), from the
pull-down menu below the Solid Info.

Note:
The desired density is derived from the printing standard you selected in Ink Set and Printing
Standard
We don't show desired density for CMYK inks for standards that use an ICC profile as a
standard profile. This is because density calculation requires spectral data, which is not
available in ICC profiles.

2. Color difference (∆E): for each ink, the ∆E should be within tolerance of the printing standard
you selected in Ink Set and Printing Standard. See Ink Set and Printing Standard on page 43
Select the ∆E Formula that is requested by the printing standard, from the pull-down menu
below the Solid Info

Note: Select an ink if you want to see the LabCh details, below the Solid Info window.

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Note: We don't show desired density, Lab and dE for the OGV inks. There are no standards for
these inks, so there's nothing to match.
c)
Accept or Reject
When your measurement is ok, it is possible to continue to the next step.

Note:
If you rejected the measurement result, you will be guided to measure again.

15. Select Measure another sample if needed.

To have an accurate and reliable curves creation, it is important that the measurements are an
average of a complete print run. Measure minimum 3 charts of good print quality (advise = 5)
a) Click Next in the lower right corner
b) You will be guided to measure again, following the same procedure (steps 12 to 14).

Note: The wizard will indicate how many charts you already measured: sample 1, sample 2, …

16. If you measured enough charts of good quality, you can select Stop measuring and inspect the
resulting screens
17. Click Next in the lower right corner.
18. Inspect the curve results
a) View at the top left an overview per ink of the original and the new curve created from the
measurements.
b) View on the right a graph of the curves.
• Colored curve: new curve created form the measurements
• Grey curve: curve from the ruling created during first setup of the printing condition
c) Select Use new adjustment curves if the new curves deviate too much from the original curves.
d) Select Use adjustment curves for xxx lpi if there is little to no difference between the new and
original curves

Note: Below the selection, a recommendation is shown made by analyzing the difference
between the curves.

19. Click Finish

Information about the new curves are added to the Screens and Curves Page of the printing condition.

6.3.2. Update Curves

As small changes, aging of printing equipment and/or fluctuations in production over time are
perfectly normal, some curves will need to be slightly modified (updated) at certain times.
At any point in the process you can stop working on your printing condition and continue later. Use the
buttons Close and Quit Now and Continue Later. Don’t forget to Save when asked.

In the Printing Conditions library, the printing condition will get the mark in front of the name.

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When you are ready to continue, start the wizard. You will be asked to Resume or to Start a new
session. Click Resume to continue editing your printing condition.

Note:
• You can continue to use the printing condition, when you didn’t finish editing.
• Only one unfinished session can be available per printing condition. You need to finish first the
current session if you want to add a new ruling or Update curves. The new session will overwrite the
unfinished session.
• It is possible to remove an unfinished task, right-click on your printing condition and select remove
unfinished task.

1. Start updating the curves:

• In the Printing Conditions library, select the printing condition and click the Update Curves

button in the bottom toolbar

• In the Printing Conditions library, right-click the printing condition and select Update Curves...
• Open the printing condition and click the Update Curves... link in the center of the Screens and
Curves overview.
2. Select the Screen Ruling you want to update the curves for.

Note: You can only select a ruling that was already added to the Printing Condition. On top, you see
an overview of the curves for every ink and ruling.

3. Click Next in the lower right corner

4. From this point on, the wizard is identical to Add Ruling on page 71. Follow steps 4 to 19 of this
procedure.

Note:
We strongly advise against editing curves and curve strategies created via the Print Control Wizard in
Curve Pilot.
Curve Pilot is an expert tool with a lot of functionality that is not needed and therefore not supported by
the Print Control Wizard.
Wrong usage of the tools could generate issues in your printing condition.
We only recommend to open the Curve strategy and PressSync curves in Curve Pilot to have a more
detailed view of the curves and to see the Curve history (for example how many times were the curves
updated + what were the previous settings).
For more information, see the Curve Pilot user guide: https://www.esko.com/en/support/product?
id=Curve%20Pilot

6.3.3. Edit White

To edit the White settings:
1. Open a printing condition: Right-click it and select Open, or double-click on a printing condition.
2. Select White
3. Click Change White setting...

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Note:
When you already completed the configuration step Screens and Curves, a warning will appear that
changing the White settings will reset the Screens and Curves and the printing condition becomes
unavailable for production.
• If you click Yes, you will need to create new screens and curves by going through all the steps
again.
• If you click No, you cannot edit your white

4. Complete all steps as described in White on page 39

6.3.4. Change Plate Making and Press Calibration Settings

If the current screening dot and surface screening are not delivering the same quality anymore, it could
be necessary to review the settings.
We recommend to only redo this step if all other possibilities failed to maintain the quality (adapt
machine settings for CDI and Press, check printing tools, …).
1. Open a printing condition: Right-click it and select Open, or double-click on a printing condition.
2. Select Plate and Press Calibration
3. Click Change plate making and press calibration settings...

Note:
When you already completed the configuration step Screens and Curves, a warning will appear that
changing the plate and press calibration settings will reset the Screens and Curves and the printing
condition becomes unavailable for production.
• If you click Yes, you will need to create new screens and curves by going through all the steps
again.
• If you click No, you cannot edit your white

4. Complete all steps as described in Plate and Press Calibration on page 28

6.3.5. Change Screens and Curves

If the current settings are not delivering the same quality anymore, it could be necessary to reset the
settings and test on press what parameters are optimal for the new circumstances.

Note: It is not possible to adapt individual settings, you need to complete all steps. If only the curves
need to be adapted, use Update Curves. See Update Curves on page 80

We recommend to only redo this step if all other possibilities failed to maintain the quality (adapt
machine settings for CDI and Press, check printing tools, …).
1. Open a printing condition: Right-click it and select Open, or double-click on a printing condition.
2. Select Screens and Curves
3. Click Set screens and curves...

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Note:
A warning will appear that changing the screens and curves settings will reset the Screens and
Curves and the printing condition becomes unavailable for production.
• If you click Yes, you will need to create new screens and curves by going through all the steps
again.
• If you click No, you cannot edit your white

4. Complete all steps as described in Screens and Curves on page 47

At the end, when clicking Finish, you will get a warning that the previous curve strategy and curves will
be deleted from the Esko resources. This includes curves for all rulings.

6.4. Exporting and Importing Printing Conditions

Printing conditions can be imported and exported from the Printing Conditions Explorer. All data
including screens, curves, measurements, Quit Now and Continue Later records, etc. are part of the
exported file.
Screens and curves that are not part of a printing condition, can also be imported and exported.
Exceptions:
• Legacy printing conditions, created by previous versions of the Print Control Wizard (18.1.1 or
lower) cannot be imported or exported via Color Pilot, as they are stored in a different database
(SQL server of Automation Engine). To Export or Import, you can use the previous Print Control
Wizard software. See the chapter Importing and Exporting Printing Conditions in the Print Control
Wizard 18.1 user guide: https://docs.esko.com/docs/en-us/printcontrolwizard/18.1/userguide/
home.html#en-us/common/pcw/task/ta_pcw_ImportExportPC.html

• Only custom screens (SCRxx) and HD Flexo (HDxx) screens can be imported/exported. Crystal
screens can only be exported via the Printing Condition. Static screens are installed by the
Automation Engine installer.
By default, most data is exported as File Packer (.fp) files.
File Packer files are archives that you can use to exchange different types of color management
settings (profiles, color strategies, ink books...) between different versions of Color Pilot/Color Engine
Pilot.

6.4.1. Exporting the Complete Library

When exporting all data from Color Pilot, you have an option to include all screens, curves and printing
conditions.
Only use this option if the data will be imported in a Color Pilot that is supporting printing conditions
(Color Pilot 20 or later, correct licenses…).
1. Select Export Library from the File menu.
2. Specify the folder where you want to save the exported archive.
a) Click Browse.
b) Select the folder.

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c) Click Save.
3. Enable the option Include screens, curves and printing conditions.
4. Enable Export as one single archive (recommended).
When disabled, all items will be exported as individual single files, which can easily be hundreds of
files.
5. It is possible to remove individual items from the export, by selecting one or more items and
clicking the Remove button.
A warning will be shown that the removed item could be linked to another item, and this item will not
work properly after import in another Color Pilot database.
6. By default, all data (except for ICC profiles) is exported as .fp files, which is only compatible with
Esko software.
Color profiles and ink books can also be exported in another open format, CxF/X-4 and CGATS
respectively. Click the triangle ( ) next to the item to change the format.
7. Specify a File Name.
8. Click Export.
A .fp file will be created in the selected folder. This could take some time.
At the end of the export, you may in some cases see a warning that some items failed to export (shown
in a list). The archive is still created, but the items from the list will not be part of the exported file.

6.4.2. Exporting Single Items

Curves, screens and printing conditions can individually be exported from their explorer.
1. Select the Screens, Curves or Printing Conditions explorer
2. Select the screen, curve or printing condition you want to export
3. Right-click and select Export or select Export from the File menu
4. Specify the folder where you want to save
5. Specify a File Name
By default the name of the item you want to export will be selected.
6. Click Save
All linked items (profiles, curves, …) will also will be exported.

6.4.3. Importing Single Items or a Complete Library

Importing a complete library is typically done when you want to restore a backup of your Color data or
share with another Esko configuration.
Importing single items is typically done when you want to share a specific setup.

1. Select Import from the File menu

2. Navigate to and select the .fp file.

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Note: You can also just drag the file onto the Color Pilot shortcut on the desktop or onto the Color
Pilot application window to import it.

3. Click Open
A list of all items in the .fp file are shown in the import dialog.
In the last column State you can see if the item will be imported, merged...
Select an item in the list to see more details about the item below, and what will happen during
import (imported or not, name that will be changed…)
If you import a single item, details will also show what the linked items are (profiles, curves…) that
also will be imported.
4.
To add extra .fp files, click the button , navigate to the .fp file and open it.
5.
To remove items from the import, select one or more items and click the button
6. Click Import Selection if you only want to import 1 or more items, or click Import All if you want to
import the complete library.
7. Check if all items were imported successfully, by verifying the State of every item.
8. If all is OK, click Close
All items that already existed (name based) in the database will be overwritten! Make sure that the data
in the .fp file is more recent than the current data in your Color Pilot.
Ink books using the same name (for example Designer) will merge the data. Inks using the same name
will be replaced by the copy in the .fp file.

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7. Printing Conditions for Corrugated

7.1. Creating a Printing Condition for Corrugated

If you are printing on corrugated material (for example packaging cardboard), you should create a
printing condition for corrugated.

Note: You need to have the corresponding license to create a printing condition for corrugated.

1.
In the Printing Conditions library, click the New Printing Condition button in the bottom
toolbar.
2. In the New Printing Condition dialog:
a) Enter the Printing Condition Name you want to use.
We recommend you use a descriptive name, that includes some of your workflow's key settings,
for example Press Type - Plate Type - Substrate.
b) In Application (the application of your flexo printing workflow, so the type of jobs and substrates
that you usually work on), select Corrugated.
c) In Board Liner, select the type of corrugated material you are printing on.
The application supports:
• Brown Kraftliner

• White Top Kraftliner

• White Coated Kraftliner

• Brown Test Liner

• Brown Kraft Top Liner

• White Top Test Liner Uncoated

• Mottled Test Liner

• White Top Test Liner Coated

d) Click OK. A new printing condition is created, and the configuration steps are shown.

Note: The printing condition is immediately saved into the database.

3. Complete all configuration steps in the printing condition editor: see Printing Condition
Configuration Steps on page 87.
4. After finishing the last configuration step, you can:
• Have a final look at the parameters and screen(s) of the printing condition: see Reviewing the
Printing Condition on page 100.

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• Create a detailed report of the printing condition: see Saving a Report on page 100.
Over time, as your equipment ages and your production fluctuates, you may need to adapt your printing
condition, see Editing Printing Conditions for Corrugated on page 101.

7.1.1. Printing Condition Configuration Steps

The Printing Condition Editor

When you open a printing condition for editing, a banner at the top displays the status of the printing
condition and a brief description of the selected configuration step.
Below the banner you see an overview of all configuration steps:
• General on page 28
• Board on page 88
• Plate Making on page 89
• Press and Inks on page 90
To navigate between the configuration steps, you can either:
• select a configuration step,
•
click the navigation arrows on the left and right of the pane:
Unfinished printing conditions have an indicator next to each step:
• : all mandatory parameters are filled in,
• : you still need to fill in some or all mandatory parameters,
• : this configuration step is not available until some mandatory parameters in previous steps are
filled in.

Filling in Parameters
• Mandatory parameters in the configuration steps are marked with a grey check mark . They all
need to be green before the configuration step is marked as completed.
• Some of the steps depend on mandatory parameters from previous steps. If you change a
mandatory parameter, you will need to redo any step depending on it.

Note:
You cannot edit any of the selection lists in the printing condition (for example substrate type, plate
type…). Only parameters that have been tested and approved can be selected.
For some parameters, what you can select depends on:
• your license,
• what you have selected in previous steps (for example, you can only select between types of optics
that are available on the model of CDI you have entered).

Pausing and Resuming Your Work

At any point in the process you can stop working on your printing condition and continue later. Use
the Save and Close or Quit Now and Continue Later buttons (depending on where you are in the
configuration).
If you are asked to confirm whether to save your work and close, don't forget to click Yes.

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When you are ready to continue, open the printing condition by right-clicking it and selecting Open, or
by double-clicking on it. The first step that is incomplete will automatically be selected, to remind you
where to continue.
If you want to remove your latest modifications in the printing condition, click the Revert button in the
bottom tool bar. Be aware that all modifications until the latest save action will be removed.
We recommend to regularly save changes (for example after every step) to make better use of Revert
and avoid unnecessary loss of time and data.

After You Are Done

When you open a finished printing condition, the interface will be a little different. See Reviewing the
Printing Condition on page 69.

General
The first configuration step in the list shows the Application that has been chosen in the New Printing
Condition dialog. It can no longer be changed.
See Creating a Printing Condition for Flexibles or Labels on page 26 or Creating a Printing Condition for
Corrugated on page 86.
You have the opportunity to enter a Description and add/remove Keywords, but this is not mandatory.

Note:
Keywords added via the Printing Conditions Explorer, will also be visible here.
See the chapter Keywords in the Color Pilot user guide: https://www.esko.com/en/support/product?
id=Color%20Pilot

Board
Define the characteristics of the board material you are printing on.
1. The Board Liner is the one you already selected.
However, you can still change it if needed. You can choose one of the following:
• Brown Kraftliner

• White Top Kraftliner

• White Coated Kraftliner

• Brown Test Liner

• Brown Kraft Top Liner

• White Top Test Liner Uncoated

• Mottled Test Liner

• White Top Test Liner Coated

2. Select the type of Board Fluting in the material you are using (A, B, C, E or F).

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3. Select the Board Style.
This can be Single Face, Single Wall, Double Wall or Triple Wall.
4. If desired, you can add a Description (to help you tell this board apart from other similar boards you
might be using).

Plate Making
In this configuration step, you need to specify what Flexo plates you use, and the way the plates are
made (image, expose, develop).
1. Select your Imager Type:
• CDI Crystal: the new generation of Esko imager, using the Crystal technology
• CDI Spark: an older generation of Esko imager
For more information about Esko's different CDI models: https://www.esko.com/en/products/
digital-flexo-platemaking/cdi-spark/models
2. Select your Optics:
• For CDI Spark: Optics15, Optics25, Optics40, Optics80 or Optics80 V2

• For CDI Crystal: Optics40 V2, Optics80 V2 or Optics100 V2

Tip: If you don't know your CDI's optics technology, you can find it in the tables below (it is linked to
its maximum imaging speed).

Table: CDI Spark (Models 2530, 4835, 4260, 5080, and 5080-C)

Maximum Imaging Speed Optics Technology

1.5 m²/hr Optics 15

2.5 m²/hr Optics 25

4 m²/hr Optics 40

8 m²/hr Optics 80 or Optics 80 v2 (depending on the

model)

Table: CDI Crystal (Models 4835 and 5080)

Maximum Imaging Speed Optics Technology

4 m²/hr Optics 40 v2

8 m²/hr Optics 80 v2

10 m²/hr Optics 100 v2

3. Choose a Resolution of either 2400 or 2540 ppi.

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Note: With a CDI Crystal with Optics 100 v2, you can only use the higher resolution, 2540 ppi.

4. Select your Exposure Type:

• XPS Crystal: Esko device that simultaneously exposes the front and back of the plate, using UV
LEDs.
• Bank: non-Esko exposure device, can be an analog or digital device.

Note: The exposure types available here depend on your license.

5. In Description, you can add information about your exposure devices, for example exposing times,
what device (if you own several exposing devices of the same type) ...
You can also add all other information that could not be specified in the default fields, information
that is important to identify how the plates are created.
6. Select your Plate Type.
A wide range of plate types from different manufacturers is available. All plates in the list are tested
and approved by Esko, to be able to guarantee a minimum quality.
In the future more plate types could be added. Contact Esko support if your plate type is not in the
list.
7. Select your plate's Thickness if desired.
Depending the plate type you selected, you will have a fixed list of plate thicknesses. Only plate
thicknesses that are tested and approved by Esko will be available.
In the future more plate thicknesses could be added. Contact Esko support if your plate thickness is
not in the list.
8. Enter your Relief Depth if desired.
This is the depth of the dots on your plate (or the difference in height between the printing surface
and the floor of the plate).
You can calculate your plate relief depth (in red below) by measuring your plate's thickness (in blue)
and subtracting the plate floor's thickness (in green).
 

Note: To change the units, see Preferred Units on page 19.

9. The Developer is always set to Solvent for plates made for printing on corrugated material.

Press and Inks

The Press and Inks configuration step is available once you filled in all mandatory parameters in the
previous configuration steps (General, Board, and Plate Making).
In this configuration step, you need to add information about your press setup.

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For every setup it is important to gather as much information as possible, to better understand the
conditions of the setup at a later time.
1. Enter the manufacturer name of your press (Press Brand).
2. Select your Press Type. It can be either:
• Central Impression press: containing a single large-diameter common impression cylinder that
supports the substrate as it enters in contact with a series of adjacent plate cylinders.
• Stack Press: in which the substrate passes through multiple color stations which are aligned in
one or two vertical stacks).
• In-line Press: in which the substrate passes through multiple color stations which are aligned in
a straight horizontal line).
3. Select your Press Size: Wide Web or Narrow Web.
4. Enter your press' Printing Speed, in sheets per minute.
5. In the Press Inks table, you can:
• Add the properties of the inks that you typically use, and choose a screen for these inks.
See Adding Inks on page 91.
• Modify the properties of one or more of the inks you have added.
See Modifying Inks on page 96.
• Remove one or more of the inks you added: select the ink in the table, click Remove Inks... and
confirm your choice.
Once you have added inks, you can see the properties of each ink, and the screen found for it, in the
Press Inks table.

Adding Inks
In the Press and Inks section of the corrugated printing condition editor, you need to add the properties
of the inks that you typically use (including what anilox and tape you use for printing with them), and
choose a screen for these inks.
You can set "default" properties that represent most or all of your inks, but you can also set properties
for specific inks, for example if you are having trouble getting the ink coverage you want with a
particular ink, or if a customer has specific requirements for some spot colors.
For default inks, and for each specific ink that you want to add:
1. Click Add Ink... under the Press Inks table.
This opens the Add Ink wizard.
2. On the Choose Ink and Workflow screen:
a) Choose for which ink you want to set properties and choose a screen:
• To set "default" properties that represent most or all of your inks, leave Other Inks selected in
the Ink field.

• To set properties for a specific ink, click the Select link and browse to your desired ink in the
pop-up that open (first select the right ink book, then your ink).

Note: You can use inks from cloud ink books. Please see the Color Pilot documentation to
learn more about cloud ink books.
b) Choose a method of entering properties and choosing a screen:

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• In most cases, we recommend that you follow the guided procedure that will help you analyze
a printed test chart to find the best screen: select Analyse a print to find the best screen.

• If you have already used the guided procedure for another ink and you want to set properties
and choose a screen for a new, but similar ink (that uses the same anilox and tape), you can
select Copy screen and printing condition properties from another ink.
In this case, click Select in the Reference Ink field, and select the ink which properties and
screen you want to copy.

• If you already know the best screen to use for the ink you are working with (for example if you
received screening settings from an external plate maker), you can select Define screen and
printing condition properties manually.
3. On the Define Printing Condition Properties screen, enter the properties of your ink(s).
See Defining Ink Properties on page 93.

Note: If you have chosen the Copy screen and printing condition properties from another ink, the
properties will already be filled in, but you can still change them if needed.

Tip:
From this point onwards, you can use the Quit Now and Continue Later button if you need to stop,
save your progress, and resume the wizard later. Make sure you click Yes in the pop-up asking
whether you want to save your work and close the wizard.

When you are ready to resume your work, you will see an unfinished task icon on the Add Inks...
button. When clicking Add Inks..., you will be asked whether you want to continue your unfinished
wizard session. Click Yes.
You can also choose to start a new wizard session instead, but you will not be able to save two
unfinished wizard sessions (the second one will overwrite the first one).

4. If you are following the guided procedure (you selected Analyse a print to find the best screen on
the Choose Ink and Workflow screen), you now need to print a test chart, and evaluate it.
See Printing and Evaluating a Test Chart on page 94.
5. On the Choose Screen step, you need to choose the best screen to use for your ink(s).

Note:
• If you are following the guided procedure, you need to evaluate the screens on your printed test
chart.
• If you are copying another ink's properties and screen, it will be already filled in, but you can
change it if desired.
• If you already know the screen to use (for example you received it from an external plate maker),
you can just fill it in.

See Choosing a Screen on page 95.

6. Click Finish, and your screen will be created (in your screens database).
You can now see your ink's properties and screen summarized in the Press Inks table.

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The Description for selected ink at the bottom shows the description you're entered when choosing
your screen.

Defining Ink Properties

On the Define Printing Condition Properties screen, enter the properties of your ink(s).

Note: If you have chosen the Copy screen and printing condition properties from another ink, the
properties will already be filled in, but you can still change them if needed.

1. Under Ink Properties:

• Enter the manufacturer of the ink (Brand).

• Select the Type: Solvent, Water-based or UV curable.

• Enter the Viscosity in seconds.

You can measure an ink's viscosity using an eux cup. The viscosity is the number of seconds
it needs to flow through the hole at the bottom of the cup until the cup is completely empty
(very viscous inks need longer). Some newer press models can measure this automatically
(electronically).

Note: The ink's viscosity affects how well it transfers onto your substrate, and can change
depending on ambient temperature and time (for example when the solvent in a solvent based ink
starts evaporating).

2. Under Anilox Properties:

• Enter the manufacturer of the anilox (Brand).

• Enter the anilox Type.

• Enter the anilox' Line Screen in lines per inch (this is the number of cells per linear inch).
A higher line screen is used for finer detail, while a lower one will transfer a heavier layer of ink.

• Enter the Angle of engraving (relative to the anilox axis) in degrees. This is typically 30°, 45° or
60°.

• Enter the anilox' Cell Volume (the ink capacity of each engraved cell) in billion cubic microns
(BCM).

Note:
The cell volume of an anilox roll can change over time, due to wear, damage and "plugging" (dried
ink residues at the bottom of the cells).
Plugging can happen when solvent or water-based ink is not cleaned immediately after using the
anilox and dries in (UV curable ink will not dry on its own).

3. Specify the Tape Properties by entering the manufacturer of the tape (Brand).

Note: We recommend to also add the tape hardness in the same field.

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Printing and Evaluating a Test Chart

After entering your ink properties, you now need to print and evaluate a test chart to find the best
screen for your selected ink.

Note: This is only applicable if you are following the guided procedure (you selected Analyse a print to
find the best screen at the start of the wizard).

1. On the Print Test Chart screen, save the LEN file that you will use to print your test chart.
This LEN file will have the resolution you entered in the Plate Making parameters.
a) If you want your test chart to be mirrored, select Mirror Image.
The chart preview is adjusted to reflect your selection.
b) If desired, you can also choose to Add default bearer bars and slur marks.
The bearer bars will support the plate while printing, and the slur marks are a small pressure
sensitive pattern that will help you check if the amount of pressure applied is correct.

Note: Adding these makes the chart slightly bigger. You can see the Chart Size above the chart
preview.
c) Click Save Chart, and browse to your desired location.
2. Print the test chart using the setup that you described.
3. The Verify Plate and Print screen guides you in checking the quality of your test chart's key areas.

You need to evaluate each area of the chart that is marked with a blue question mark on
screen.

Tip: For each step, click the Learn more about evaluating this area link to open a document with
more information and guidelines.

a) In the first step, Check Dot Fail, you need to check the quality of the individual dots.

If the quality is good, click the green check mark and continue to the next step.

If it isn't, click the red cross . In this case you need to troubleshoot the problem that is
causing the low quality dots (this is typically a plate problem but can sometimes be a press
problem), print a new test chart, and evaluate the dots again.
b) In the Check Slur Marks step, you need to check whether the slur marks printed correctly.
The slur marks are pressure sensitive, and the pattern will not look correct if there is either too
little or too much pressure applied during printing. For example, you may have missing lines
if there is too little pressure, or missing white space between the lines if there is too much
pressure. The lines may also look wavy instead of straight, or smudged.

If the slur marks look good, click the green check mark and continue to the next step.

If they don't, click the red cross . In this case you need to troubleshoot the pressure problem,
print a new test chart, and evaluate the slur marks again.
c) In the Check Lines step, you need to check whether the different line thicknesses printed
correctly.

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This is to make sure that any barcodes in your print jobs will be printed correctly.

If the lines look good, click the green check mark and continue to the next step.

If they don't, click the red cross . In this case you need to troubleshoot the problem, print a
new test chart, and evaluate the lines again.
d) In the Check Fluting step, check whether you can see the fluting pattern coming through the
printed image.
If this is the case, there is too much pressure applied during printing.
If the image looks good (you cannot see the fluting pattern through it), click the green check
mark .

If you can see the fluting pattern, click the red cross . In this case you need to troubleshoot
the pressure problem, print a new test chart, and evaluate again.
e) When you have found that all areas are satisfactory, click Next.

Choosing a Screen
On the Choose Screen step, you need to choose the best screen to use for your ink(s). More
specifically, you need to choose the best surface screening for your solids, as all screens
recommended by the application for corrugated printing are variants of the Crystal NP (Non-Pixel+) C
screen.
The right surface screening pattern will give you a good ink coverage while optimizing your ink usage.
Some inks may not need a surface screening pattern.
1. In the Surface Screening list, select the option that gives you the best result for your printed solids.
All options are surface screening patterns, except (A) Solid, which prints the solid as it is, without
surface screening.

Note:
• If you are following the guided procedure, you need to evaluate the screens on your printed test
chart.
Click the Learn more about choosing surface screening for corrugated link to open a
document with more information and guidelines.

• If you are copying another ink's properties and screen, it will be already filled in, but you can
change it if desired.

• If you already know the screen to use (for example you received it from an external plate maker),
you can just fill it in.

2. If desired, you can also enter a Description (for example, of the result obtained with your chosen
surface screening versus other ones).
3. Click Finish, and your screen will be created (in your screens database).
You can now see your ink's properties and screen summarized in the Press Inks table.

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Modifying Inks
Once you added some inks (you defined ink properties and chose a screen for either all "default" inks, or
certain specific inks), you can change those properties later if needed.
1. In the Press Inks table, select the ink you want to modify and click Modify Ink... (you can also
double-click the ink).
This opens the Modify Ink wizard.
2. On the Choose Workflow screen, choose a method of entering properties and choosing a screen:
• In most cases, we recommend that you follow the guided procedure that will help you analyze a
printed test chart to find the best screen: select Analyse a print to find the best screen.

• If you have already used the guided procedure for another ink and you want to set properties and
choose a screen for a new, but similar ink, you can select Copy screen and printing condition
properties from another ink.
In this case, click Select in the Reference Ink field, and select the ink which properties and
screen you want to copy.

• If you already know the best screen to use for the ink you are working with (for example if you
received screening settings from an external plate maker), you can select Define screen and
printing condition properties manually.
3. On the Define Printing Condition Properties screen, the properties of your ink(s) are filled in. Modify
them as desired.
See Defining Ink Properties on page 93 for more information.

Tip:
From this point onwards, you can use the Quit Now and Continue Later button if you need to stop,
save your progress, and resume the wizard later. Make sure you click Yes in the pop-up asking
whether you want to save your work and close the wizard.

When you are ready to resume your work, you will see an unfinished task icon on the Add Inks...
button. When clicking either Add Inks... or Modify Inks..., you will be asked whether you want to
continue your unfinished wizard session. Click Yes.
You can also choose to start a new wizard session instead, but you will not be able to save two
unfinished wizard sessions (the second one will overwrite the first one).

4. If you are following the guided procedure (you selected Analyse a print to find the best screen on
the Choose Workflow screen), you now need to print a test chart, and evaluate it.
See Printing and Evaluating a Test Chart on page 94.
5. On the Choose Screen screen, you can select a different surface screening pattern if desired, and
fill in/edit the Description.
See Choosing a Screen on page 95 for more information.
6. Click Finish when you are done editing your ink.
You can now see your ink's updated properties and screen summarized in the Press Inks table.
The Description for selected ink at the bottom shows the description you're entered when choosing
your screen.

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Defining Ink Properties

On the Define Printing Condition Properties screen, enter the properties of your ink(s).

Note: If you have chosen the Copy screen and printing condition properties from another ink, the
properties will already be filled in, but you can still change them if needed.

1. Under Ink Properties:

• Enter the manufacturer of the ink (Brand).

• Select the Type: Solvent, Water-based or UV curable.

• Enter the Viscosity in seconds.

You can measure an ink's viscosity using an eux cup. The viscosity is the number of seconds
it needs to flow through the hole at the bottom of the cup until the cup is completely empty
(very viscous inks need longer). Some newer press models can measure this automatically
(electronically).

Note: The ink's viscosity affects how well it transfers onto your substrate, and can change
depending on ambient temperature and time (for example when the solvent in a solvent based ink
starts evaporating).

2. Under Anilox Properties:

• Enter the manufacturer of the anilox (Brand).

• Enter the anilox Type.

• Enter the anilox' Line Screen in lines per inch (this is the number of cells per linear inch).
A higher line screen is used for finer detail, while a lower one will transfer a heavier layer of ink.

• Enter the Angle of engraving (relative to the anilox axis) in degrees. This is typically 30°, 45° or
60°.

• Enter the anilox' Cell Volume (the ink capacity of each engraved cell) in billion cubic microns
(BCM).

Note:
The cell volume of an anilox roll can change over time, due to wear, damage and "plugging" (dried
ink residues at the bottom of the cells).
Plugging can happen when solvent or water-based ink is not cleaned immediately after using the
anilox and dries in (UV curable ink will not dry on its own).

3. Specify the Tape Properties by entering the manufacturer of the tape (Brand).

Note: We recommend to also add the tape hardness in the same field.

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Printing and Evaluating a Test Chart

After entering your ink properties, you now need to print and evaluate a test chart to find the best
screen for your selected ink.

Note: This is only applicable if you are following the guided procedure (you selected Analyse a print to
find the best screen at the start of the wizard).

1. On the Print Test Chart screen, save the LEN file that you will use to print your test chart.
This LEN file will have the resolution you entered in the Plate Making parameters.
a) If you want your test chart to be mirrored, select Mirror Image.
The chart preview is adjusted to reflect your selection.
b) If desired, you can also choose to Add default bearer bars and slur marks.
The bearer bars will support the plate while printing, and the slur marks are a small pressure
sensitive pattern that will help you check if the amount of pressure applied is correct.

Note: Adding these makes the chart slightly bigger. You can see the Chart Size above the chart
preview.
c) Click Save Chart, and browse to your desired location.
2. Print the test chart using the setup that you described.
3. The Verify Plate and Print screen guides you in checking the quality of your test chart's key areas.

You need to evaluate each area of the chart that is marked with a blue question mark on
screen.

Tip: For each step, click the Learn more about evaluating this area link to open a document with
more information and guidelines.

a) In the first step, Check Dot Fail, you need to check the quality of the individual dots.

If the quality is good, click the green check mark and continue to the next step.

If it isn't, click the red cross . In this case you need to troubleshoot the problem that is
causing the low quality dots (this is typically a plate problem but can sometimes be a press
problem), print a new test chart, and evaluate the dots again.
b) In the Check Slur Marks step, you need to check whether the slur marks printed correctly.
The slur marks are pressure sensitive, and the pattern will not look correct if there is either too
little or too much pressure applied during printing. For example, you may have missing lines
if there is too little pressure, or missing white space between the lines if there is too much
pressure. The lines may also look wavy instead of straight, or smudged.

If the slur marks look good, click the green check mark and continue to the next step.

If they don't, click the red cross . In this case you need to troubleshoot the pressure problem,
print a new test chart, and evaluate the slur marks again.
c) In the Check Lines step, you need to check whether the different line thicknesses printed
correctly.

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This is to make sure that any barcodes in your print jobs will be printed correctly.

If the lines look good, click the green check mark and continue to the next step.

If they don't, click the red cross . In this case you need to troubleshoot the problem, print a
new test chart, and evaluate the lines again.
d) In the Check Fluting step, check whether you can see the fluting pattern coming through the
printed image.
If this is the case, there is too much pressure applied during printing.
If the image looks good (you cannot see the fluting pattern through it), click the green check
mark .

If you can see the fluting pattern, click the red cross . In this case you need to troubleshoot
the pressure problem, print a new test chart, and evaluate again.
e) When you have found that all areas are satisfactory, click Next.

Choosing a Screen
On the Choose Screen step, you need to choose the best screen to use for your ink(s). More
specifically, you need to choose the best surface screening for your solids, as all screens
recommended by the application for corrugated printing are variants of the Crystal NP (Non-Pixel+) C
screen.
The right surface screening pattern will give you a good ink coverage while optimizing your ink usage.
Some inks may not need a surface screening pattern.
1. In the Surface Screening list, select the option that gives you the best result for your printed solids.
All options are surface screening patterns, except (A) Solid, which prints the solid as it is, without
surface screening.

Note:
• If you are following the guided procedure, you need to evaluate the screens on your printed test
chart.
Click the Learn more about choosing surface screening for corrugated link to open a
document with more information and guidelines.

• If you are copying another ink's properties and screen, it will be already filled in, but you can
change it if desired.

• If you already know the screen to use (for example you received it from an external plate maker),
you can just fill it in.

2. If desired, you can also enter a Description (for example, of the result obtained with your chosen
surface screening versus other ones).
3. Click Finish, and your screen will be created (in your screens database).

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You can now see your ink's properties and screen summarized in the Press Inks table.

7.1.2. Reviewing the Printing Condition

After finishing the last configuration step (Press and Inks), you can see This Printing Condition is ready
to be used! in the banner on top, and a green check mark on the right.

The configuration steps no longer have an indicator ( , , ) next to their name.

1. Navigate between the configuration steps and view the selected parameters.
2. Check if all parameters are correct. See Editing Printing Conditions for Corrugated on page 101 if
you want to correct some settings.

Note: Be careful if you want to edit mandatory parameters ( ), some configuration steps will be
reset and you will have to repeat these steps. A warning will be shown.

3. Save a report, if needed. See Saving a Report on page 100.

4. Click Close to return to the Printing Conditions Explorer. See Printing Conditions Explorer on page
21.

7.2. Saving a Report

It is possible to save a report (PDF) for a finished printing condition.
If desired, you can customize the report by adding your logo.
1. Open the Save Report dialog:
• In the Printing Conditions library, select the printing condition and click the Save Report button

in the bottom toolbar.

• In the Printing Conditions library, right-click the printing condition and select Save Report...
• Open the printing condition and click the Save Report... button in the lower right corner.
2. Specify a File name. The default name will be: Name of printing condition_Report.pdf.
3. Choose the folder where you want to save the report:
a) click Browse...
b) select the folder,
c) click Save.
4. Select a different Banner if desired, for example if you want to add your logo on the report.
a) click Browse...
b) browse to the location and select the file,
c) click Open.
You will see a preview of your banner. Supported file formats are .jpeg, .png, .gif and .bmp. The
size of the banner area is 20cm by 2,7cm. Larger or smaller images will be resized.
Click Reset if you want to return to the default Esko banner.
5. Enter a Description if you want to add extra information to the report.

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6. Click Save.
The report (.pdf) will be saved in the selected folder and will open automatically in the default
application of the Windows Operating System.
It will include all the parameters you entered in your corrugated printing condition, and the screen to be
used for each defined ink.

7.3. Editing Printing Conditions for Corrugated

As small changes, aging of printing equipment and/or fluctuations in production over time are
perfectly normal, you may need to make some small changes to your printing condition in the future.
For example, if the current surface screening is not delivering the same quality anymore, it could be
necessary to review the settings.
We recommend to only do this if all other possibilities (adapting CDI and press machine settings,
checking printing tools…) failed to maintain the quality.
1. Open the printing condition: right-click it and select Open, or double-click it.
2. In the General step, you can edit the Description and Keywords.
3. In the Board step:
• You can change the Board Fluting, Board Style and Description as you wish.
• If you want to change the Board Liner, you will need to redo the step about choosing a screen for
your inks.
4. In the Plate Making step, changing any of the essential parameters (marked with a green check )
means that you will need to redo the step about choosing a screen for your inks.
5. In the Press and Inks step, you can add or modify inks (and choose screens for these inks).

7.4. Exporting and Importing Printing Conditions

Printing conditions can be exported and imported from the Printing Conditions Explorer.
The exported file will contain all of the printing condition's data: parameters, screens, Quit Now and
Continue Later records...
By default, most data is exported as File Packer (.fp) files. File Packer files are archives that you can
use to exchange different types of color management settings (profiles, color strategies, ink books...)
between different versions of Color Pilot.

Exception
Legacy printing conditions, created by previous versions of the Print Control Wizard (18.1.1 or lower)
cannot be imported or exported via Color Pilot, as they are stored in a different database (Automation
Engine's SQL server).
To export or import these, you can use the previous Print Control Wizard software. See the chapter
Importing and Exporting Printing Conditions in the Print Control Wizard 18.1 user guide: https://

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docs.esko.com/docs/en-us/printcontrolwizard/18.1/userguide/home.html#en-us/common/pcw/task/
ta_pcw_ImportExportPC.html.

7.4.1. Exporting a Printing Condition

You can export individual printing conditions from the Printing Conditions Explorer.
The exported file will contain all of the printing condition's data: parameters, screens, Quit Now and
Continue Later records...
1. Right-click the printing condition you want to export, and select Export... (or go to File > Export).
2. Browse to your desired location, change the File Name if desired, and click Save.
By default the name of the archive will be [printing condition name].fp.
File Packer (.fp) files are archives that you can use to exchange different types of color
management settings (profiles, color strategies, ink books...) between different versions of Color
Pilot.

Note:
For each ink used in the printing condition, the complete ink book will be included in the printing
condition export (unless it is a read-only ink book).

7.4.2. Exporting the Complete Library

When exporting all data from Color Pilot, you have an option to include all screens, curves and printing
conditions.
Only use this option if the data will be imported in a Color Pilot that is supporting printing conditions
(Color Pilot 20 or later, correct licenses…).
1. Select Export Library from the File menu.
2. Specify the folder where you want to save the exported archive.
a) Click Browse.
b) Select the folder.
c) Click Save.
3. Enable the option Include screens, curves and printing conditions.
4. Enable Export as one single archive (recommended).
When disabled, all items will be exported as individual single files, which can easily be hundreds of
files.
5. It is possible to remove individual items from the export, by selecting one or more items and
clicking the Remove button.
A warning will be shown that the removed item could be linked to another item, and this item will not
work properly after import in another Color Pilot database.
6. By default, all data (except for ICC profiles) is exported as .fp files, which is only compatible with
Esko software.

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Color profiles and ink books can also be exported in another open format, CxF/X-4 and CGATS
respectively. Click the triangle ( ) next to the item to change the format.
7. Specify a File Name.
8. Click Export.
A .fp file will be created in the selected folder. This could take some time.
At the end of the export, you may in some cases see a warning that some items failed to export (shown
in a list). The archive is still created, but the items from the list will not be part of the exported file.

7.4.3. Importing a Printing Condition

You can import printing conditions that have been exported to the File Packer (.fp) format.
1. Select the exported printing condition(s) to import:
a) Either:
• go to File > Import,

• press Ctrl+Alt+E,

• right-click in the main pane of the Printing Conditions explorer and select Import...
b) Browse to the printing condition(s) to import.
You can select several printing condition files using the Shift key, or select all printing condition
files using Ctrl+A (if the location you browsed to only contains printing conditions).

Tip: You can also just drag the printing condition to import into your Color Pilot window.

2. In the Import dialog that opens, you will see that the printing condition(s) have the state Ready
for import.
If desired, you can:
a) Change the name of the file(s) in the Import as column.

Note: If you have another printing condition with the same name, your printing condition will be
imported as [printing condition name]_2) by default.
b) Add or remove printing conditions to import using the + or - buttons.
c) Review any printing condition information shown on the Details tab.
3. Import the printing condition(s) by either:
• Selecting the printing condition(s) to import (using Shift to select several printing conditions)
and clicking Import Selection at the bottom right.
• Clicking Import All to import all printing conditions in the dialog.
You will see a progress bar, and import details on the Logging tab at the bottom of the dialog.
Once the printing conditions are imported, they will have the Imported state.
If you select an imported printing condition, you can see its contents on the Details tab at the
bottom of the Import dialog.
4. When you are done, Close the Import dialog.

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Note:
Importing a printing condition will also add the ink book(s) and ink(s) used in this printing condition to
your database.
If there is already another ink book with the same name, they will be merged.

7.4.4. Importing a Complete Library

Importing a complete library is typically done when you want to restore a backup of your Color data or
share with another Esko configuration.

1. Select Import from the File menu

2. Navigate to and select the .fp file.

Note: You can also just drag the file onto the Color Pilot shortcut on the desktop or onto the Color
Pilot application window to import it.

3. Click Open.
A list of all items in the .fp file are shown in the import dialog.
In the last column State you can see if the item will be imported, merged...
Select an item in the list to see more details about the item below, and what will happen during
import (imported or not, name that will be changed…)
4. Click Import Selection if you only want to import 1 or more items, or click Import All if you want to
import the complete library.
5. Check if all items were imported successfully, by verifying the State of every item.
6. If all is OK, click Close
All items that already existed with the same name in the database will be overwritten! Make sure that
the data in the .fp file is more recent than the current data in your Color Pilot.
Ink books using the same name (for example Designer) will merge the data. Inks using the same name
will be replaced by the copy in the .fp file.

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8. Using a Printing Condition in Your

Workflow
 

 
1. After prepress, you send your ready-to-RIP files to Imaging Engine.
2. In Imaging Engine, you select the printing condition you made with the Print Control Wizard.
See Using Your Printing Condition in Imaging Engine on page 105 for details.
3. After RIP'ing your files, it's time for Flexo Plate Making, using either:
• automated plate making in Automation Engine,
• manual plate making using Grapholas or the Digital Flexo Suite.

Note: When working with version 18.0.1 or later of Imaging Engine and the Print Control Wizard
and preparing your plates manually, you need version 18.1 or later of Grapholas or the Digital
Flexo Suite software.

For more information, see the "CDI Workflow" chapter of your Automation Engine manual, or your
Grapholas/Digital Flexo Suite documentation.
4. You image and expose your flexo plate using the devices and settings you entered in the Print
Control Wizard.
See Plate and Press Calibration on page 28 and Plate Making on page 43
5. You print your files on your press using the hardware and consumables you entered in the Print
Control Wizard.
See Substrate on page 42, Ink Set and Printing Standard on page 43, Press Settings on page 45 and
Screens and Curves on page 47

8.1. Using Your Printing Condition in Imaging Engine

Once you created a printing condition containing the optimal screens and curves to use for your
production workflow, you can use this printing condition when RIP'ing your files with Imaging Engine.

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To do this:
1. In Automation Engine, open the Image to Screened Separations ticket
2. Select your printing condition in the Printing Condition field (above the other settings).
For more information, see the chapter Image to Screened Separations in the Imaging Engine –
powered by Adobe user guide: https://www.esko.com/en/support/product?id=Imaging%20Engine
%20-%20powered%20by%20Adobe

Note:
• You can only use a printing condition that you have completed (you can see a green check when
you open the printing condition in the Print Control Wizard).
If you are still working on your printing condition in the Print Control Wizard, you will not be able to
select it in Imaging Engine.

• After making a printing condition for your production workflow, you should always use it in Imaging
Engine when printing with that production workflow.
If you make changes to your workflow (for example you print on a different substrate, or you switch
to a different ink vendor), we recommend you make a new printing condition in the Print Control
Wizard.

Selecting a printing condition automatically fills in some of the Image to Screened Separations
settings, but not all of them! Settings that are set by the Printing Condition, get the indication <set by
Printing Condition>.
It is still possible to overrule an individual setting manually and ignore the value from the printing
condition.
If all settings of the printing condition are used, the task uses the angles, ruling, screens and curves
from the printing condition.

Note:
If you didn’t specify settings for spot colors in your printing condition (selected <none> at the end
of the Screens and Curves setup - see Screens and Curves on page 47), the ticket settings will be
automatically applied for spot colors in the job.
If you change a ticket setting (Dot, Angle Set or Ruling), only the spot colors will get the new parameter.
The inks that are defined in the Priniting Condition, will continue using the settings from the printing
condition.

Note: Legacy printing conditions, created by earlier versions of the Print Control Wizard (18.1.1
or lower) can still be used, but you will notice some different behavior in the Image to Screened
Separations ticket. For example as angles are not defined in legacy printing conditions, they will not
set in the ticket. You have to use the angles from file or set them with the ticket functionality.

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