Editor’s note: Kevin Ward has helped newspapers around the world plan and implement digital workflows. Following is some of his advice based on his experience with Creo systems and software.

The decision to go digital means more than installing a platesetter. The workflow in front of the computer-to-plate device must be carefully considered as well, since it can drive additional economies and efficiencies and help deliver a strong ROI.

When you’re planning the workflow for your CTP system, it’s easier to think in terms of phases. Most newspapers move from one phase to the next as they become more sophisticated in digital technologies.

Getting ready for CTP

Whatever phase you choose, be sure you’re ready for CTP before the installation crew arrives. It’s essential that you’re able to create plate-ready film, where one page-paired file represents one plate. If you have a workflow where one file equals one plate, you’re probably ready to download that file to your new CTP platesetter.

Phase one: CTP with a minimal front end

While some newspapers see the benefits in replacing legacy RIPs with new, higher-performance systems, some choose to keep their existing RIP. The minimal front-end CTP system is one in which pages are manually paired using layout software, then RIPed and output to controller software such as Print Console. As long as your RIP can output 1,200-dot-per-inch TIFF files, it’s all you need for basic CTP.

However, not all RIPs can provide 1,200 dpi TIFFs. Some legacy RIPS output in non-standard file formats, and the resolution is often 1,000 or 1,016 dpi. We see that with parallel film-and-CTP systems, where one RIP outputs files for both a filmsetter and a platesetter. We also see it with printers that receive pre-RIPed files from their customers or from transmit sites.  

The solution is file conversion. There are several conversion tools on the market, including the Creo Copydot Toolkit. It converts file formats and resolutions without the moirŽ problems that can show up, and does other things as well, like positive-to-negative conversion, which is useful for files originally intended for film output.

This minimal system is perfectly functional if your system has enough RIP power. You manually feed work in and manually select whether page pairs are left-justified or right-justified. If you’re dealing with a lot of plates, you will soon have the problem of identifying which plate is which. When that happens, you should move up to an automated workflow. Automation turns prepress into a production line.

Phase two: Basic workflow with automated page pairing

Based on my experience, I recommend an automated workflow. It allows you to reap the benefits of streamlined production. Page assembly is labor-intensive and error prone and if you’re outputting quads, or doing any complex page layouts, the job becomes exponentially more difficult. An automated workflow will really help your ROI: It will reduce labor, accelerate production and minimize the opportunity for error. With reduced costs and a higher-quality finished product, you’ll see higher revenues.

Whatever workflow system you use, first set up the software for your newspaper’s sections and editions. The software then takes the individual pages that are sent by the layout system. The operator does not have to generate printer pairs or quads - a workflow (Creo offers Synapse NewsManager; other vendors have similar apps) does it for them. It waits until all the pages of a pair or quad are available, then automatically generates the output. Pages are released when ready; they do not have to be released in a specific order.

Automated software makes everything easier: if you’re pairing a color page and a black-and-white page for example, the software knows that there has to be a half-blank page for each of the C, M, and Y plates.

As you’re imposing pages onto plates, you may need to rotate them left and right, or left and right-justify them, or center them on the plate. The software, not the operator, takes care of all those details, to prevent operator mistakes and save wasted plates.

There are plenty of newspapers running with configurations similar to this, and they’re realizing a very good ROI.

Phase three: Automated workflow with load balancing

Depending on your volume requirements, you may need more than one platesetter and more than one RIP. In this case, a load-balancing workflow is important to maximize your resource usage and get the most from your investment. With load balancing, you typically also gain redundancy management. Together, these ensure maximum throughput; you automatically route jobs to machines with different plate sizes and automatically re-allocate work if a device fails.

Phase four: Automated workflow with edition management

When there are several editions of a paper, layout becomes far more complex and requires edition-management features in the workflow software. Here’s an example: When there are two or more editions, you have a series of page pairs, each containing some components that are the same in all editions, and some components that appear in certain editions only. This means multiple files - for example, let’s say there are two editions, and a page pair with a right-hand page that changes.

For this, we need three files: the common left-hand page, the edition 1 right-hand page and the edition 2 right-hand page. The system knows to expect the three files, to generate two plate sets. When it receives two of the files, it automatically produces one plate set (it may also add annotations that tell the operator which plates they are). When the third page arrives, the system automatically produces the next plate set. Any update to the common page will produce two new plate sets, both containing the updated page.

The edition management features in workflow software offer comprehensive control over the many variable elements. They help newspapers manage their processes easily and repeatably.

Choosing a workflow

When you’re ready to supplement your CTP with a digital workflow, take these points into consideration:

*How easy is it to use? Ease of use means less training and greater operator efficiency.

*Will you need soft (onscreen) or hard-copy proofing? Does this need to be color-correct proofing, or for position and content only?

*Can you re-output plates easily, or will each file need to be re-RIPed?

*Is your communications infrastructure adequate?

*Is there a fail-over process for data as well as communications? Has it been tested?

*Will you need different plate orientations or sizes? If so, can you control plate output order, to minimize lost time due to loading and unloading different sizes?

*Will you have sufficient production time to generate the same plate image in different resolutions, orientations, etc?

*Are the variations predictable in advance, or will manual intervention be required to define lateral reversals, rotations, etc. at production time?

*Will you use contract printers? Do they require specific resolutions or formats? Do they already have CTP? Will compatibility be an issue?

*In the event of CTP engine failure, can the system detect the failure and use alternative resources?

*Will computer-to-film be used as a backup? Do you need to retain CTF devices (and compatibility)?

*Is monitoring and control centralized or spread throughout your organization?

*Can the system output plates early? At a pre-defined time?

*Can one digital element generate several output plates?

Considering each of these points can help you to make the best workflow decision for your particular newspaper and to make the transition more smoothly.