A pressroom procedures audit by an experienced ink technician can identify trouble spots and possible solutions which can increase efficiency and reduce waste. The goal is that the correct inks are delivered to the correct press at the correct time in the correct amount.

An audit checklist should start with these items and add more as appropriate:

Scheduling and Production Logistics
-Number of job changes and color matches per time.
-Amount of ink returned at the end of the job.

In-Plant Ink Base/Colorant/Vehicles
-Colorant checked for color strength
-Unused portions saved how long?

New Color Matches
-Proofing procedure
-Work-offs not used in new ink color matches.
-Standard formulas recorded, filed.

In-Plant Ink Production
-Wet standards used
-Comparative proofing
-Color approval procedure (eye/computer)
-Work-off procedure formalized for repeat batches

Prior to Job Startup
-Ink delivery systems checked for cleanliness
-Inks mixed, checked
-pH check, adjusted

Job Startup
-Viscosity measurement devices clean, calibrated (as required)
-Use prior run data for setup
-Ink viscosity checked (as required)
-Ovens at operating temperature
-Standard used to check color (proof/swatch), done at press speed
-Lighting for color check

Press Run
-pH measurement and control
-Maintain viscosity
-Document run data

Cleanup Procedure
-Draining and wash-up
-Ink delivery system cleanup
-Handling of press returns

Ink Inventory Control
-Storage and labeling of press returns
-Re-use procedure

Safety
-Ink and solvent handling procedures
-Cleanliness

Training 
-Pressroom personnel familiarization with ink and ink handling, press setup
-Training procedure
-Sales, marketing and design personnel familiarization with ink and hardware
capabilities.
-A written report should be presented to management. Lead off with the good news
and break the bad news easily as suggestions.

Author: Stanley Field
Source: Gravure, Fall 1999, p. 42-44.