Xerox 2000 User Manual

Introduction

A new way to look at documents
An overview of the DocuColor 2000 Series Design Guide

1. Digital print 1-1

What is digital print? 1-1
Digital print workflow 1-3

Document creation 1-3
Prepress 1-3
Press 1-5
Postpress 1-5

Correction required? 1-5
What does digital print mean to you? 1-6
Benefits of digital print 1-6

Short runs 1-6

Just-in-time printing 1-7

Distribute and print 1-8

Variable information printing 1-9

Use of colour 1-10
Wrap-up 1-10

2. Image reproduction process 2-1

DocuColor 2000 Series technology 2-1

Printing stations 2-1

Digital Blanket 2-2

BeltNip fuser 2-2

TRACS 2-3

Precise Registration System 2-3

Decurling devices 2-3
Print speeds/productivity 2-3
Image size/paper size 2-5
Screens 2-5
Gamut 2-7
Process colours 2-8

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Table of Contents

3. Designing documents 3-1

Design elements to discuss with your printer 3-1

Paper stock 3-1
Image considerations 3-2
Image area, bleeds and folds 3-4
Specifying colours 3-7
Choice of screens 3-7
Vignettes 3-16
Text 3-17
Solid blacks 3-19
Image mottle 3-19
Knockout, overprint and trapping 3-20
File formats 3-21
Resource collection 3-21
Creating PDFs 3-22
Dot gain 3-23

Design elements to avoid 3-23

Straight design elements close to the edge of the page 3-23
Large areas of solid colour 3-25
Coated stock and large white text on heavy background 3-26

4. Submitting jobs 4-1

Print submission 4-1
Compatible software 4-1
Printing overview 4-2

Print from Microsoft Windows and Apple Macintosh workstations 4-4
Print direct from a Digital Front End 4-10
Submit jobs via a PostScript Downloader Application 4-13
Submit jobs using an Internet browser 4-15
Submission of PDF Files for print 4-17
In summary 4-19

5. Selecting paper stock 5-1

Stock considerations 5-1
Digital printing process 5-1
Paper influences on print quality 5-2

Formation 5-2
Grain direction 5-2
Weight 5-3
Finish 5-3

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DocuColor 2000 series design guide

Why paper doesn’t always work the way it should 5-3

Coated paper and offset 5-3

Coated paper and digital printing 5-3

Moisture and offset 5-4

Moisture and digital printing 5-4

Textured stock and offset 5-4

Textured stock and digital printing 5-4
Thick paper stocks 5-5
Coated papers 5-5
Paper stretch 5-5
Optical paper qualities that influence image quality 5-6

Shade 5-6

Opacity 5-6

Brightness 5-6

Reflectivity 5-7
Paper grades 5-8

Bond 5-8

Uncoated offset 5-9

Text and covers 5-11

Coated offset 5-12

Uncoated digital 5-13

Cover 5-13

Index or Bristol 5-15
Paper handling and storage 5-16
Wrap-up 5-17

6. Binding and finishing 6-1

Collating 6-1
Folding and scoring 6-1

Scoring 6-2

Types of folds 6-2
Binding 6-4

Saddle stitching 6-4

Side stitching 6-4

Edition binding 6-5

Perfect binding 6-5

Mechanical binding 6-6

Looseleaf binding 6-6
Finishing touches 6-7

Trimming 6-7

Die cutting 6-7

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table of contents

Lamination 6-7
Varnish 6-8
Embossing 6-8
Shrink wrapping 6-8

Double-sided printing 6-9

7. Applications by industry 7-1

Financial services 7-1
Consumer products 7-6
Hospitality 7-10
Professional services 7-13
Education 7-15
Health care 7-18
Public sector 7-21

Appendix 1. Microsoft Office colour charts 1

Appendix 2. RGB colour charts 1

Appendix 3. CMYK colour charts 1

Appendix 4. Pantone colour charts 1

Reference 1

Glossary 2

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DocuColor 2000 series design guide

A new way to look at documents

One of the greatest advantages of digital colour applications and systems is that they
allow high-quality colour process printing to be produced in smaller quantities at a
higher frequency, as well as personally tailored printing to optimise customer interaction.
Digital printing technology changes the way we think about and create documents.
Limitless possibilities are now accessible for full-colour, near-offset quality printing
at a reasonable price.

Until recently, highly trained imaging experts working on expensive proprietary systems
typically performed most imaging tasks such as colour enhancement and image
manipulation. New technologies and desktop publishing applications have changed all
that, enabling designers to complete many of these tasks from their desktop computers.

The more knowledgeable you are about the imaging process from document creation to
output, the easier it will be to maximise your results. This guide offers suggestions that
will help you get the most out of your imaging applications when preparing files to
print on a Xerox DocuColor 2045 or 2060 digital colour press.

An overview of the DocuColor 2000 Series Design Guide

The DocuColor 2000 Series Design Guide has been written to provide you with all the
information you need to ensure you get the highest quality printed documents from the
DocuColor 2045 and 2060 with the minimum of fuss – every time. It is divided into
sections for easy reference.

• Section 1 covers the topic of digital print, describing what it is, the workflow, and
the key benefits digital print offers designers and customers. Use this section to
learn more about digital print and what it offers.

• Section 2 details the key attributes of the DocuColor 2000 Series. It examines some
of the technology used and details performance and printing characteristics. Use
this section to learn more about the capabilities of the DocuColor 2045 and 2060.

• Section 3 provides guidance on how to design your documents to get the best
possible results from the DocuColor 2045 and 2060 and avoid design elements that
may cause problems. Use this section as a guide to ensure you design documents
that will result in perfectly printed documents every time.

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Introduction

• Section 4 includes information on how to submit jobs to a DocuColor solution,
directly from software applications on Windows or Macintosh personal computers,
over the web, using removable media, or other means. Use this section to make sure
you get the job to the printer trouble-free every time.

• Section 5 describes how to select the right paper to get optimum results from the
DocuColor 2045 and 2060. It includes a guide to all paper grades available in the
market today. Use this section to learn more about paper and to choose the best
paper for the job.

• Section 6 provides information on binding and finishing – the final steps to ensure
a perfect, finished piece. Use this section as a guide to various binding and
finishing options available from your printer.

• Section 7 examines different industry segments and identifies key applications, the
department or person responsible for that application, and the key benefits of using
digital colour print for that application. Use this section as a guide to finding
digital colour applications in different market segments.

• Appendix 1 includes charts of Microsoft Office colours. Use this section as a guide
to how Microsoft Office colours are reproduced on the DocuColor 2045 and 2060.

• Appendix 2 includes charts of RGB colours. Use this section as a guide to see how
RGB colours are reproduced on the DocuColor 2045 and 2060.

• Appendix 3 includes charts of CMYK colours. Use this section as a guide to select
CMYK colours as they are reproduced on the DocuColor 2045 and 2060.

• Appendix 4 includes charts of Pantone colours. Use this section as a guide to see
how Pantone colours are reproduced on the DocuColor 2045 and 2060.

•The Reference section includes references to other documents and material. Use this
section as a reference to find more information on particular topics and issues.

•The Glossary section includes definitions of digital printing terms. Use this section
to check words or abbreviations that may be unfamiliar to you.

If you have any suggestions on how this Design Guide can be improved, please send
your comments to [e-mail].

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DocuColor 2060 design guide

Digital technology has changed many facets of business and industry today.
Computing and communications technology has allowed companies to revolutionise the
manufacturing process – from producing goods and then hoping to sell them, to just-in­time production, where products are sold first and then manufactured to order, reducing
waste, inventory and cost. It has also allowed them to produce products more in tune
with individual customer’s needs, moving from mass production to mass customisation.

Computing and communications technology has also allowed companies to gain access
to new markets. No longer are they tied to local markets, but instead can compete in
a global market.

Countless examples exist of how digital technology has changed the face of business
across all industries, from agriculture to information technology. Banks, for instance,
still provide banking and lending services, but have closed branches in favour of ATMs,
and internet and phone banking. The music and entertainment industry has seen the
appearance of CDs, DVDs and game boxes, and the disappearance of LPs and cassettes.
Still photography, video and television broadcasting is transitioning to digital. The way
people communicate now is by mobile phone, facsimile and e-mail – instant
communications to anyone anywhere on the planet.

Digital technology has also dramatically changed the nature of the document – a document
today can still be a sheet of paper or book, but is more likely to be an electronic file,
a spreadsheet, presentation, scanned image, or a clip with video and music. Computers,
desktop publishing applications, digital imaging and printers have allowed millions of
people to create documents on their desktop that used to take a team of people weeks
to develop.

Consumers today are more demanding. They know what they want and they’re not prepared
to wait. It’s no different in their demands for print: high quality, cost effective, and now!

What is digital print?

In simple terms, digital print is where information to be printed is submitted electronically
(ie, in digital form) to the printer, where it is imaged and the printed material produced.

There are numerous digital printing technologies available, including inkjet, electro­photography with dry or liquid toner, thermal transfer, ionography and magnetography.
Even traditional offset presses with direct imaging (or DI) are promoted as “digital presses”.

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1 Digital print

What truly distinguishes digital printing from traditional printing is the ability to print
every page differently. This is something that offset presses – including DI presses – can­not do. Offset presses can only print exact replicas of the same sheet, again and again.

The digital colour presses that dominate the market now – and for the foreseeable
future – are all toner based. They utilise electrophotography, either with liquid toners
(Indigo), or dry toners (IBM, Kodak-Heidelberg, MAN Roland, Xeikon and Xerox).

The market for colour print can be split into segments defined by run length and
specific applications. The suitability of different printing technologies to these
segments is as follows:

Digital Direct Conventional

colour imaging (or DI) offset

Segment/application printing offset presses printing

One-off and one-at-a-time publications Yes No No
Customised/personalised documents Yes No No
Vert short runs (<500) Yes No No
Short runs (501-2,000) Yes Yes No
Moderate runs (2,001-5,000) No Yes Yes
Long runs (5,001-50,000) No No Yes
Very long runs (50,001+) No No Yes

With the many benefits of digital colour printing (described later in this section), we
are seeing a strong swing toward shorter runs. The table below shows that in 1998, 28%
of all print volume in the US was short run, but in less than 20 years it is expected to
account for almost half of all print volume.

1998 2000 2010 2020

Ultra Short Run (1) 8% 10% 13% 14%
Very Short Run (2-500) 10% 13% 15% 16%
Short Run (501-2,000) 10% 13% 15% 17%
Moderate Short Run (2,001-5,000) 17% 15% 16% 16%
Moderate Run (5,001-10,000) 14% 13% 11% 11%
Average Run (10,001-50,000) 12% 9% 8% 7%
Moderate Long Run (50,001-250,000) 11% 11% 9% 8%
Long Run (250,001-750,000) 9% 7% 6% 5%
Very Long Run (750,000+) 9% 9% 7% 6%

100% 100% 100% 100%

Source: Professor Frank Romano, Graphic Media Briefing, 29 March 2001.

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DocuColor 2000 series design guide

Digital print workflow

The entire process for the production of a printed document can be broken-down into
three phases: prepress (which includes all steps after the design is completed up to the
point where the job is printing), press or printing (the printing phase), and postpress or
finishing (all the steps required to finish the job after printing and before distribution).
Digital printing has greatly simplified two of these phases: prepress and press.

For an understanding of how digital printing has streamlined the production of printed
documents, it’s useful to compare it with the workflow associated with traditional offset
printing. The following discussion greatly simplifies the entire production process, but is
sufficient to highlight the major steps involved in each workflow. (See diagram page 1-4)

Document creation

The first step in the production of a printed document requires the creation of a design.
A concept is developed into a layout, followed by the preparation of text (writing,
editing, font selection and typesetting) and artwork and images (which can include
electronic illustrations, scanned photographs, digital camera shots or stock library
images). The document is then ready to be created, generally using a page assembly
program to combine the text and image elements.

Computers, software and digital technologies have already revolutionised the creation of
documents. Typesetting (the assembly of type into words and lines) used to be done by
hand. Illustrations were created by hand and photographs were always film-based. The
assembly of these text and image elements was a manual process, called pasteup, with
the end result being a camera-ready copy. Today, almost all documents are created
electronically, totally eliminating the need for these time-consuming and error-prone
manual processes.

Prepress

Once a document is created, it can be proofed (proofing is a simulation of how the job
will look when it is printed).

If you are having your job printed on a DocuColor 2045 or 2060, you can also run a
proof on the press which will show you how the job will look when it is run. This is
called a “press proof” (because it is proofed on the actual press) and will show you
exactly how the job will look when it’s printed.

If you are printing on a traditional offset press, a proof at this stage will only
approximate what the final result will look like. Fonts may look different (because

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digital print

different RIPs are used) and colours will not match exactly. A proof can be produced on
a digital device (like a DocuColor printer or inkjet or dye sublimation system) or using a
photomechanical system (like Cromalin). The advantage of digital systems is that they
have a lower cost and quicker turnaround, and they better fit the digital workflow most
use today. However, photomechanical systems are still used where film is an important
part of the workflow.

If everything is acceptable with the proof, you can then approve the job and have it
printed. If, on the other hand, changes are required, the design needs to be edited and
the steps above repeated.

If the job is ready and is to be printed on a DocuColor 2045 or 2060, there’s no more to
do – the job can be RIPped and printed.

If the job is to be printed on an offset press, plates need to be produced for the
printing process. Traditionally, this involves the production of film from which the plates
are made. Prior to the introduction of digital solutions, this involved producing
photographic negatives or positives (film) of the camera-ready copy. Today, imagesetters
are used to produce film directly from electronic files. The film is then assembled and
light-sensitive plates (or image carriers) are exposed to visible light, UV radiation or
lasers in a photomechanical process to make the plates.

Newer technologies today allow printers to produce plates or image carriers directly from
electronic files. Called CTP (short for Computer-to-Plate) or DI (short for Direct Imaging
on a press), these technologies are designed to streamline the prepress requirements of
offset presses.

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DocuColor 2000 series design guide

K

Y

M

C

DIGITAL PRINT WORKFLOW

CAPTIONS TO BE SUPPLIED

Press

The job is now at the stage where it’s ready to be printed.

If the job is being printed on a DocuColor 2045 or 2060, the operator will have
calibrated the press earlier in the day and loaded the right paper. The job is then
RIPped (using the appropriate settings) and printed. It doesn’t matter whether you want
1 copy or a thousand, the process is the same.

On an offset press, the operator needs to set the press to make it ready for printing
(called makeready). This process can take anywhere from 10 minutes to an hour and
requires the use of a skilled operator. It can involve steps such as inking, dampening,
cleaning and loading plates. Once the press starts printing, it will take several prints
(sometimes hundreds of prints) for the press to settle and be adjusted correctly so that
it is matches the proof as closely as possible. These prints are called waste and are
thrown-away or recylced. Once the press is set and printing correctly, it will print exact
copies of the same image again and again.

Postpress

Once printing is completed, the job is ready to be finished. This can include tasks such
as trimming, folding, binding, packing and delivery to the customer.

Correction required?

If you’ve received your job and noticed that something’s not right (for example, the
address is wrong), you’ll need to reprint the job.

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digital print

With the DocuColor 2045 and 2060, you’ll make the change to the file and re-submit the
job. The printer will re-RIP the job and print it. Done.

With the traditional offset process, you would also change the file and re-submit the job.
Now the printer will have to create a new set of film, new plates, set the press up again,
and then start printing. More steps for something to go wrong and more waste produced.

What does digital print mean to you?

New opportunities: added document value combining technology with your creativity.

New solutions: improved customer satisfaction and loyalty.

Cost reductions: elimination of print storage and distribution costs.

Speed: getting mission-critical information where it needs to be faster.

Focus: documents customised to your audience one-to-one.

Management: creative revisions and/ or reprints whenever and wherever needed.

Digital print is about you, the designer, combining your creativity with new print
technology to deliver more effective communication between business and customers.

Digital print is about getting improved response rates on direct mail, faster turnaround
for brochures, and minimising outdated material. It’s about time to market, reacting
quickly to changing market dynamics and capturing market opportunities – without
blowing the budget.

Benefits of digital print

There are four main areas where digital colour print can deliver real benefits: cost
effective short run printing, printing on demand, just-in-time, distributing documents
electronically and printing them locally, and targeting customers with personalised
content utilising variable information printing.

Short runs

The key strength of traditional offset printing is that once the press is set, it prints
long runs cost effectively. Recent developments with offset presses have been aimed at
reducing the set-up (or make-ready) time in order to make the presses more cost
effective at shorter runs. However, anybody wanting short runs of high quality colour
work has until recently had few choices – either pay a very high unit price, print many
more copies than required (most of which would be wasted), or accept that the work
can’t be done economically.

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DocuColor 2000 series design guide

The DocuColor 2045 and 2060 now allow consumers of print to have high quality colour
work printed cost effectively on short runs – anywhere from a one-off up to 2,000
copies. You no longer have to buy long print runs to drive unit costs down.

Because a digital press prints each page differently, you can even print one book at-a­time in a single print run.

Examples of applications now possible with digital printing include:

•Short run books

• Limited run video covers and CD labels and jewel case inserts

• Business cards

• Conference, trade show or seminar publications

•Test marketing material

•Brochures

•Newsletters

• Annual reports for small companies or review copies for the board

•Proposals

•Market research reports, survey reports, environmental impact reports

•Menus, invitations and greeting cards

With digital colour printing you can now print exactly the quantity you require, not the
quantity your printer wants you to buy.

Just-in-time printing

The just-in-time manufacturing process has revolutionised many industries, such as the
personal computer, whitegoods, brown goods and car industries. It reduces inventory and
eliminates wastage, leading to cost savings and improvements in productivity. Print buyers
want to share the same advantages, and digital printing delivers on these benefits.

The DocuColor 2045 and 2060 have markedly reduced prepress requirements, especially
in comparison with both DI and traditional offset presses (which require lengthy make­ready work) as well as most other digital colour presses. This means that work can be
turned around very quickly – within the day, hours or even minutes. No other printing
technology can match the turnaround time of a digital press.

Combine the quick turnaround time with the short run economics of digital print means
that you can print on demand only what you require. Files can be stored electronically,
eliminating the need to store and retrieve paper documents. This significantly reduces
non-print costs associated with the storage, wastage and distribution of out-of-date
documents. Studies show that 30-50% of all printed material is thrown out unused.

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digital print

As the life cycle of products gets shorter and shorter, it means that with digital print
you will always have the latest, most up-to-date, accurate and relevant support material
and publications. It allows you to frequently update the content of your printed
material and print small batches of the latest version, avoiding the distribution of
incorrect or out-of-date material.

Examples of applications suited to the just-in-time advantages of digital printing include:

•Manuals •Brochures

• Catalogues • Financial reports

•Presentations • Books

• Conference and trade show material

With digital colour print you will no longer print material just in case you need it, you’ll
print it when you need it, on demand, just in time.

Distribute and print

Traditionally, print buyers would order ample quantities of print to meet all foreseeable
needs, print it in one run, and then ship it to all those locations that required copies of
the publication. This process is time consuming, costly, and prone to delay, as
documents are shipped around the country or around the world.

With digital printing and the power of the internet, documents can be sent
electronically anywhere around the world and printed locally on a digital press at the
point of delivery. An editor can sign-off on a document in Sydney and have it printing
in minutes in Melbourne, London, Paris and New York. This eliminates delays in the
production process, reduces shipping costs, and ensures that up-to-date publications are
in the hands on consumers in a timely manner.

You can even version your documents to tailor them for regional readers

Examples of documents ideally suited to the distribute and print model include:

•Newspapers • Financial reports

•New product brochures • Limited edition books

•Newsletters

No longer do you need to print first and wait for it to be distributed, you can now
distribute your document instantly world-wide and have it printed locally without delay.

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DocuColor 2000 series design guide

Variable information printing

A unique characteristic of digital print is the ability to print every page differently. Not
only does this mean you can print a multi-page document (like a book) in a single print
run, but you can also personalise each sheet or page to an individual. It is achieved by
changing certain text (like name and address) and/or images on the page. This new
capability is called variable information printing (or variable data printing), which
people may also call personalisation, customisation or versioning.

Although this capability is not new (it’s been used for many years to produce bills and
statements), what’s exciting is that this capability is now available in full colour,
including graphics and images.

Personalised refers to a document that has been tailored to a specific individual.
Although it could be a simple mail merge, a personalised document may often have
unique combinations of paragraphs, pictures, and other information directly targeting
the individual.

Customised is used to describe any document that has been altered, in a sense
customised, to its audience. It is derived from a common document template with
different messages and content based on stated customer preferences.

Versioned or targeted lots is used to describe documents based on data-mining
techniques. Several versions of a document are created based on selection of target
criteria, such as broad demographics, psychographics or purchase history data. The
document appears personalised but is identical to that produced for other recipients
with the same profile. Catalogues, newspapers and manuals are good candidates for
versioning.

Variable information printing has allowed marketeers to target customers with specific
products and services, tailored to their individual needs. Companies can today leverage
the vast amount of information they possess about their customers with this capability.

It also allows companies to protect their most valuable strategic asset – their
customers. Communicating with each customer individually allows organisations to
solidify a direct, one-to-one relationship with their clients.

Marketeers can improve the investment value of mailings by utilising variable
information printing. Even by adding the simplest personalisation to a direct mail piece
– name and address – response rates can increase by 36% (1997 CAP Ventures report).

This is especially important in these days where marketeers are wanting to get closer to
their customers, have fewer dollars to spend, and are demanding measurable results.
Variable information printing is perfectly placed to meet these goals.

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digital print

Use of colour

Colour attracts attention, increases impact, stimulates emotions, and touches us where
pure reason and intellect do not. Use of colour in documents improves understanding
and comprehension, helps organise data, and aids the reader in decision-making,
learning, retention and recall.

Numerous studies back the power of colour. Ronald E Green (The Persuasive Properties of
Color, October 1984) showed that colour sells products and services better by up to 85%
and provides savings in time taken to read of 70%. D Hoadley et al (Investigating the
effects of Colour, Fonts and Bold in Text Documents, January 1996) demonstrated that
colour increases understanding by up to 74% and recollection rates by up to 77%, and
reduces error counts by up to 55%. And Case and Company (Grasp Facts Fast with Color
Copying, July 1974) showed that colour increase reader motivation by up to 80%.

The benefits of colour apply to all documents. Add impact to presentations and
proposals, improve response times and response rates with direct mail and bills, increase
readability of statements and reports, and improve learning and recollection of training
material and manuals. Colour improves your company’s professional image and enhances
all types of documents.

Until recently, colour was too expensive to use in everyday applications. With the
introduction of Xerox solutions like the DocuColor 1250, 2045 and 2060, everyone
now has the ability to produce high quality full colour documents at an affordable
price – no matter whether you need one copy or a thousand.

Wrap-up

Economical short runs Quick turnaround

Rapid response to market changes Cost effective publications

High quality print for professional image Reduced print inventory

Eliminate print wastage Reduce print costs

Distribute and print Print what you need, when you need

Documents always up-to-date Personalised documents

Reprints on demand One book at a time

Communicate with each customer individually Affordable colour

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DocuColor 2000 series design guide

The DocuColor 2045 and 2060 are digital colour presses with the ability to produce
superb print quality on a broad range of paper stocks. This section includes a
description of the technology that’s built into the presses that allows them to deliver
on their promise as well as providing information on some of the capabilities of the
DocuColor 2000 Series that will help you in designing documents for the press. This
includes topics such as size considerations, print speeds, available colours, print
resolution and screens available.

DocuColor 2000 Series technology

The DocuColor 2045 and 2060 were developed to meet the demands of customers for
extremely high quality print, production-oriented feeding and finishing, paper versatility,
and cost-efficiency.

Never before has a digital colour press come so close to offset quality so easily. The 600 x
600 x 8 dpi print resolution consistently provides users with sharp, clear text and vibrant,
true-to-life images. The untrained eye will find it difficult to tell the difference between
jobs output from the DocuColor 2045 or 2060 and those produced on offset presses.

The print engine houses the brains, heart and muscle that drive the DocuColor 2045 and

2060. It uses state-of-the-art, patented technology that ensures high image quality and
productive, reliable output.

Printing stations

Inside the DocuColor 2045 and 2060 there are four printing stations – one for each
process colour, cyan (C), magenta (M), yellow (Y), and black (K). Each station houses
extra-large cartridges that hold a mixture of dry ink and developer. A Xerox process
called Trickle Charge Development (the mixture of dry ink and developer) constantly
replenishes the print stations with fresh dry ink and developer, which ensures a more
consistent image quality over longer periods of time and through longer runs.

Xerox engineers found that with xerography, full-colour images come out looking truer
when the dry ink/developer is laid down on the blanket in an atypical order: yellow,
magenta, cyan, black. Placing the process colours on the blanket in this order, rather
than in the standard cyan, magenta, yellow, black used with offset presses, improves
the integrity and vibrancy of greens whilst maintaining that of the other colours,
including yellows, reds and blues.

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2 Image reproduction process

Digital Blanket

Significant improvements in image quality can be attributed to the Digital Blanket used
in the DocuColor 2000 Series. The Digital Blanket passes under the four printing stations
where the image is transferred to the blanket. The four colours of the image are
assembled on the blanket – one on top of another in perfect register – and then
transferred to the paper in a single pass when the blanket passes under a pressure
roller. The uniform, flat surface of the Digital Blanket reduces image quality defects and
extends the range of stock that can be reliably supported.

BeltNip fuser

The imaged paper then travels toward the BeltNip fuser, crossing two vacuum transports
which keep stocks moving along smoothly. The BeltNip fuser is another technological
innovation that ensures each image is fused properly to the stock. It consists of a roller
and a belt that ensures stocks stay against the heated roller for the longest possible
time for a complete fix of the image. A long dwell time is especially important for heavy
stocks and jobs with heavy area coverage to fuse well, and to compensate for the
increased speed of printing of the press.

The BeltNip fuser also uses LOFT (Low Oil Fusing Technology), which reduces oil usage
to a fraction of previous generation printers. This enhances the appearance of final
output and reduces operating costs.

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DocuColor 2000 series design guide

TRACS

To ensure consistency from first print to last, the DocuColor 2000 Series utilises a
technology called TRACS (Toner Reproduction Auto Correction System). TRACS
automatically measures 16 levels of density and colour, and makes adjustments on the
fly. TRACS works by placing CMYK density patches directly on the Digital Blanket
between pages as they circulate through the machine. These patches are then read by
built-in auto density control sensors, and any quality adjustments are made on the fly.
The result is consistent and reliable colour from start to finish.

Precise Registration System

Important to total high quality output is image to page registration. On the DocuColor
2045 and 2060, stock is passed over three aligner transport rolls which de-skew the
stock by applying the appropriate amount of pressure based on the substrate’s weight
and size. A registration roll then centres the stock to the image on the Digital Blanket.
Centring the stock cuts down on sheet-to-sheet and front-to-back registration errors by
half. Two timing registration sensors also regulate the speed of the Digital Blanket
(which regulates the speed of the stock) for more accurate, more consistent image-to­blanket registration and image-to-page registration.

Decurling devices

When dry ink is fused to paper, especially with heavy coverage, there is a natural
tendency for the paper to curl.

To eliminate curling, the stock passes through two of three decurling devices. The devices
look at the weight of the stock, the print coverage, and whether the job is simplex or duplex
(when the stock is duplexed, it passes through all three decurling devices). The devices
remove curl and produce flat, uniform output that runs smoothly through the press.

Print speeds/productivity

With very heavy or very light substrates, print speed must decrease to ensure quality.
With the DocuColor 2045 and 2060, the machine will always print at optimum speed in
accordance with the stock being used. The most popular stock weights are printed at
the maximum speed available.

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image reproduction process

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DocuColor 2000 series design guide

Print speeds of the DocuColor 2060 are as follows (in images per minute):

A4 A3 SRA3

64 – 80 gsm: 45 ipm 30 ipm 22.5 ipm
81 – 135 gsm: 60 ipm 30 ipm 30 ipm
136 – 220 gsm: 30 ipm 15 ipm 15 ipm
221 – 280 gsm: 22.5 ipm 15 ipm 7.5 ipm

The DocuColor 2045 prints slower than the 2060. Print speeds are as follows
(in images per minute):

A4 A3 SRA3

64 – 80 gsm: 45 ipm 30 ipm 22.5 ipm
81 – 105 gsm: 45 ipm 30 ipm 30 ipm
106 – 150 gsm: 30 ipm 15 ipm 15 ipm
151 – 280 gsm: 22.5 ipm 15 ipm 7.5 ipm

The production speed of the DocuColor 2060, in single-sided sheets per hour, is follows:

A4 A3 SRA3

64 – 80 gsm: 2,700 1,800 1,350
81 – 135 gsm: 3,600 1,800 1,800
136 – 220 gsm: 1,800 900 900
221 – 280 gsm: 1,350 900 450

The production speed of the DocuColor 2045, in single-sided sheets per hour, is follows:

A4 A3 SRA3

64 – 80 gsm: 2,700 1,800 1,350
81 – 105 gsm: 2,700 1,800 1,800
106 – 150 gsm: 1,800 900 900
151 – 280 gsm: 1,350 900 450

Image size/paper size

The DocuColor 2045 and 2060 accept standard paper sizes of A4, A3 and SRA3. They will
also accept non-standard paper sizes, from 182 mm to 320 mm in height, and 182 mm
to 488 mm in width.

The DocuColor 2045 and 2060 will print to within 4 mm of each paper edge. The following
table provides the imageable area for different paper sizes.

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image reproduction process

Paper size name Paper size Image area

Minimum paper size 182 x 182 mm 174 x 174 mm
A4 210 x 297 mm 202 x 289 mm
A3 297 x 420 mm 289 x 412 mm
SRA3 320 x 450 mm 312 x 442 mm
Maximum paper size 320 x 488 mm 312 x 480 mm

Screens

Screen ruling is a measurement of lines per inch (lpi) or number of lines (or rows) of
halftone dots printed per inch on the page. When an image has a high screen ruling,
the dots are printed close together, resulting in sharp colours and images. Low screen
rulings print dots farther apart, resulting in a coarser effect. High screen rulings are
typically used for higher quality output on less porous surfaces (eg, gloss coated stock),
while low screen rulings are used for more porous surfaces that are prone to dot gain
(eg, newsprint).

When you print in colour, the rows of CMYK dots are printed in individual screens. One
layer is used for each base colour (ie, one cyan, one magenta, one yellow, and one
black). These screens are then overlapped and printed to create the illusion of multiple
colours. Screens are angled, forming a symmetrical pattern called a rosette so that the
dots don’t print on top of each other. Your eye easily merges these patterns into smooth
colour gradations.

The DocuColor 2045 and 2060 use a calibrated 200 cluster dot screen, as default, to
achieve their crisp image quality. Four other screens are available (600 fixed line, 300
fixed line, 200 rotated line and 150 cluster dot) for specific customer effects. For
example, the 600 screen could be used for pages containing only text, the 150 cluster
dot could be used to ‘soften’ a greyscale image.

A highly magnified picture of the 200 cluster dot screen is shown below for three input
density levels.

The next section, Designing documents, provides examples of the different screens
available on the DocuColor 2045 and 2060, and recommendations for their use.

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DocuColor 2000 series design guide

PLEASE SUPPLY ORIGINAL PIC

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image reproduction process

Gamut

The gamut (or range of colours) that the human eye can see is much larger than the range
of colours that can be reproduced in a photograph, on a television or computer display, or
in print. Also, every device capable of reproducing colour has a different gamut. The
gamut of an RGB computer display is larger than the CMYK gamut of a DocuColor 2000
Series system, which in turn is larger than the CMYK gamut of an offset press.

The primary reason the gamut of a DocuColor 2045 or 2060 is broader than the CMYK
gamut of an offset press is due to the purity and vibrancy of the dry ink used in the
DocuColor.

Process colours

Process colours are produced by printing overlapping screens of cyan, magenta, yellow
and black. Since the DocuColor 2045 and 2060 do not print “spot” colour like an offset
press, you have the ability to mix and blend variations of CMYK to create virtually
limitless colour palettes. Refer to Appendix 3 for examples of some of the CMYK colours
the DocuColor 2045 and 2060 can produce.

Even though the DocuColor 2045 and 2060 cannot run spot colours, they can convert
Pantone colours into CMYK process colours on the fly during the RIP stage. Both the
Fiery and Creo RIPs will convert Pantone colours into process colours, but their
conversion techniques are slightly different. Please refer to Appendix 4 for examples of
how the Pantone colours are reproduced on the DocuColor 2045 and 2060.

The DocuColor 2045 and 2060 can match about 75% of all Pantone colours to within a
Delta-E (DE) of 5. DE is a scientific measurement of colour difference with a DE of 0
being a perfect match. For colour matching, a DE of 5 is acceptable, but anything
greater than 5 is usually rejected as being an unsatisfactory match. Offset presses using
process colours can generally match no more than 50% of Pantone colours.

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DocuColor 2000 series design guide

C C, M C, M, Y C, M, Y, K

Graphic designers today have a broad choice of mediums they can use to communicate
ideas and designs, including traditional print technologies – like litho, gravure or flexo
– or newer technologies, like the web, multi-media CD, or digital colour presses.

Every medium presents its own set of challenges for the design community. For example,
with offset presses you need to consider issues like sheet size, screening used, ink
density and dot gain. With the web, you’ll need to conform to recognised standards,
ensure links and anchors work, and that your fonts and images work. The more you
know about your medium, the better you are able to design for it.

This section will help you design smarter, sexier-looking documents without having to
endure the steep learning curve normally associated with new technologies and mediums.

Knowing what design elements work best on a DocuColor 2045 or 2060 will make it
easier for you to set up your files for optimum printing, streamlining the print process
and avoiding any last minute corrections. You should consider the issues discussed
below to ensure a smooth, trouble-free print run of the highest quality available from
digital printing today.

Design elements to discuss with your printer

Elements that need forward consideration with your printer

Paper stock

With printing, paper quality has a direct relationship to print quality. Therefore it’s
important you review Section 5, Selecting paper stock, before committing to a job.

The DocuColor 2045 and 2060 will print on a broad range of stocks: coated and uncoated
stocks, specialty stocks and transparencies. Paper weight can range from 64 gsm to
280 gsm and size can vary from 182 x 182 mm to 320 x 488 mm.

The most versatile stock for the DocuColor 2000 Series is the Xerox Colotech+ uncoated
range of stocks. They offer more forgiveness than coated stocks, which more readily
display any print artifacts such as oil streaking. Coated stocks are also more prone
to paper stretch when passing through the heated fuser roll, so bleed and design will
need to be carefully considered when using coated stocks. Due to paper stretch, it is
recommended to include at least 3 mm of bleed on all documents.

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3 Designing documents

Image considerations

Whether your original image is a transparency, photographic print or digital file, the
image characteristics you start with will have a major impact on the end results. As with
any other high quality print medium, the lower the quality of your source image, the
poorer the quality of your reproduction. There is simply no substitute for quality images.

Most common layout programs (QuarkXPress, InDesign, PageMaker) can be used to
supply artwork for the DocuColor 2045 and 2060. They will work with all popular,
standard image file formats, such as EPS, TIFF, JPEG, BMP, etc. You can use CMYK or
RGB files – the colour management software in the Creo and Fiery RIPs will convert RGB
images into the CMYK mix required for the press.

In terms of image resolution, the same 300 dpi images used for offset are equally suitable
for printing on the DocuColor 2045 and 2060. As with any offset print run, images of
lower resolution can be used, with a compromise in ultimate image quality. On the other
hand, images with resolution greater than 600 dpi (the print resolution of the DocuColor
2000 series) will only waste processing time and will not give you better results.

The images on the opposite page will allow you to make your own judgement on image
quality, with images ranging from 300 dpi down to 72 dpi. If high image quality is not
your prime requirement, then using lower image resolutions will result in faster
processing time.

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DocuColor 2000 series design guide

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designing documents

300dpi 225dpi

150dpi 72dpi

Where offset has a total ink limit of around 350%, digital printing has a lower limit of
around 280%. This requires images to have UCR or GCR applied either at the time of
scanning, or when they are RIPped. If you scan images with UCR, do so with a maximum
ink limit of 280%. The Creo and Fiery RIPs used with the DocuColor 2000 Series will
automatically apply ink reductions to jobs when RIPping and limit ink to 280% (or any
other amount with the Creo). This ink reduction does not affect image quality.

Note that the total ink limit refers to the maximum amount of ink or toner in any given
area on the paper, such as in a black area. To calculate, add together the CMYK dot
percentage values in the darkest area in the image, eg, C96, M88, Y88 and K75 =
96+88+88+75 = 347%. The theoretical maximum is 400% (100% each of C, M, Y and K).

Image area, bleeds and folds

The maximum sheet size the DocuColor 2045 and 2060 will accept is 320 x 488 mm,
however this is a non-standard sheet size and not readily available (it must be cut to
order). SRA3 – 320 x 450 mm – is the most commonly used sheet with a maximum
image area of 312 x 442 mm.

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DocuColor 2000 series design guide

The DocuColor 2000 Series presses will accept standard paper sizes of A4, A3 and SRA3,
as well as non-standard paper sizes from 182 mm to 320 mm in height and 182 mm to
488 mm in width. They will print to within 4 mm of each paper edge. The following
illustrations highlight the image area for different paper sizes.

A3 size

297 x 420 mm

Maximum image size

312 x 442 mm

SRA3 paper size

320 x 450 mm

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designing documents

Minimum paper size

182 x 182mm

Image area

174 x 174mm

A4 paper size

210 x 297mm

Image area

202 x 289mm

A3 paper size

297 x 210mm

Image area

289 x 412mm

Bleed is recommended to be at least 3 mm all around to allow for any front to back
image skew on the DocuColor 2045 and 2060 (which has tolerance of 1 to 1.5 mm).

Folding any stock can result in paper cracking on the spine, therefore it is recommended
that for best results, all sheets that are to be folded be run through a scoring unit. This
is especially important when printing areas of dark colour across folds (if the stock is
not scored, the paper cracks will show as white lines through the colour). See Section
6, Binding and finishing, for more information.

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DocuColor 2000 series design guide

SRA3 paper size

320 x 450mm

Image area

312 x 442mm

Maximum paper size

320 x 488mm

Image area

312 x 480mm