Sony DADC

Reference Book - Label

Printing Process, Labelprint without white pre-printing,
Disc variants, Tips & Tricks for Designer

Solutions by Sony DADC

 Sony DADC Label
1. Printing Process

1.1. General Page 3 Information and examples

1.2. Screen Printing Page 4 Information and examples

1.2.1. PANTONE Colours Page 4 Information and examples
1.2.2. Screen colours (KNRC) Page 5 Information and examples
1.2.3. Metallic colours (8000) Page 6 Information and examples
1.2.4. Pastel colours (9000) Page 6 Information and examples
1.2.5. Fluorescent colours 801-814 Page 6 Information and examples
1.2.6. Special colour (SF) Page 6 Information and examples
1.2.7. Clear varnish Page 7 Information and examples
1.2.8. Matt varnish (DXX-0998) Page 7 Information and examples
1.2.9. Sniffle colours Page 8 Information and examples
1.2.10. Thermal varnish Page 8 Information and examples
1.2.11. Inkjet varnis Page 8 Information and examples

1.3. Offset Seite 8 Information and examples

2. Labelprint without white pre-printing

Labeldruck without white pre-printing Page 9 Information and examples

3. Disc variants

Disc variants Page 10 Information and examples

4. Tips & Tricks

4.1. Setting Black to overprint Page 10 Information and examples

4.2. Marabu Black (#34) - KNRC 65 (#54) Page 10 Information and examples
4.3. 4C Offset Black Page 10 Information and examples
4.4. Individual white base Page 10 Information and examples
4.5. Equal raster angle Page 11 Information and examples
4.6. Line Width Page 11 Information and examples
4.7. Client proofs Page 11 Information and examples

More important informations for creating Graphic-Files

Reference Book Tips for creating Grafic-Files

Reference Book Template
Reference Book PDF from InDesign including ICC Profile, Distiller Settings and Preflight
Reference Book PDF from XPress including ICC Profile, Distiller Settings and Preflight
Reference Book PDF from Corel Draw including ICC Profile, Distiller Settings and Preflight
Sony DADC Download Area

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Sony DADC Printing Process

1. Printing Process

1.1. General

When printing a disc the company of Sony DADC distinguishes between screen- and offset printing, whereby both are
dependent on design and data build-up and each have their advantages and disadvantages.
Solid coated PANTONE colours, which we mix directly, are generally used for screen printing. This procedure is generally
used for simple designs or areas. (Fig 1)

Fig 1 Screen Print - Pantone (#34

Sony DADC also offers the picture print (4C Screen print- CMYK) in screen printing. This print is mainly used for
simple pictures that barely show gradients and have more than 6 colours (therefore nor possible in PANTONE).
(Fig 2)

Fig 2 Screen Print - Picture (#54)

The offset print allows Sony to print low tone values and all kinds of pictures. (See also Fig 3)

Fig 3 Offset (#80)

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Sony DADC Printing Process - Screen Print

1.2. Screen Print

1.2.1. PANTONE Colours

- All Sony screen print machines are equipped with 6 print heads.
This means a max. of 6 colours can be printed.
For example: White + 4 colours + varnish
White + 5 colours....
- The PANTONE colours do not cover completely 100%, which means if two colours are printed over each other
slight colour changes can occur. This is why fine components and texts must be left out of Pantone colours.

Exceptions:
- Black and Silver (P877C) are covering
- Duplex-pictures in which a light and dark PANTONE colour are used
- The screen print PANTONE colours always have a glossy surface - that is why PANTONE references of PANTONE
UNCOATED cannot be accepted.
- PANTONE possesses a maximum screen width of 34 lines/cm (85lpi). These pantone colours are not suitable
for screening, because the screen points with such a rough screen are clearly visible. The screen points would
blur with a higher screen. The tone value should at least reach 10% since the screen points would otherwise
be too small for the screen and therefore not be printable.
- If large areas are printed in screen, the tone value should not have over 90% (also counts for KNRC colours), or
else the area could smear up, which leads to an uneven, cloudy result. For that reason a alternative PANTONE
colour (printed in 100%) is recommended for large screen areas.
- Lines must have a width of at least 0.10mm (positive) and 0.15pt (negative) to achieve an optimal result.
- The letter size of the text must at least amount to 4pt (positive) and 5pt (negative). (Fig 4)

min. 0,15mm min. 0,10mm

A a B b C c D d Ee Ff Gg
A a B b C c D d E e Ff Gg

Hh Ii Jj Kk Ll Mm Nn Oo Hh Ii Jj Kk Ll Mm Nn Oo

Pp Qq Rr Ss Tt Uu Vv Pp Qq Rr S s Tt Uu Vv

Fig 4 min. 4pt (1,50mm) min. 5pt (1,88mm)

- PANTONE colours are normally always printed on white. If this is not desirable the client has to be informed,
that the colour changes and does not match the PANTONE spectrum. (Fig 5)

without white with white

pre-print pre-print

Fig 5

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Sony DADC Printing Process - Screen Print

- Gradients are not recommended in PANTONE, because this leads to edges that influence the result.
(Fig 6 and 7)

Fig 6 Fig 7

1.2.2. Raster colours (KNRC):

- The colours for the CMYK- screen print (= picture print = KNRC) are transparent like conventional offset
colours and consequently have the same colour mixing characteristics.
- These colours are especially designed for screen print with fine screen widths and have explicitly less dot
increase than PANTONE colours. With KNRC- colours a screen width with a max. of 54 lines/cm (133lpi)
is possible.
- But there are also severe quality losses with screen colours if designs with large areas consist of one or more
screened colours (Moire, smear effect). Such designs should be done with PANTONE if possible or the client
should be advised to switch to offset print.
- Transitions or fine elements (such as faces) should not be printed in picture, because of dot loss in the lighter
areas which changes the colour in the design. In this case one should recommend the offset print to the client
as well. (illustration bottom)

Proof Offset : equal printing Picture : high colour variation

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Sony DADC Printing Process - Screen Print

1.2.3. Metallic colours (8000 + P871C-P877C):

The metallic colours from the 8000th- series are developed for the print without white pre-print. The reflexion
characteristic of the disc silver enhances the metallic effect. (Fig 8)
Therefore white pre- prints under metallic colours change the shade on the one hand but on the other hand the metallic
effect deteriorates (Fig 9). If the client agrees with this, it must be noted in the check sheet (subsequently abbreviated
with CHS). P877C is excluded from this regulation, because the amount of metallic pigments is very high in this colour!

ohne Wei mit Wei

Fig 8 Fig 9

1.2.4. Pastel colours (9000):

The pastel colours from the 9000th- series should always be used with white pre- print, because the disc silvers reflexion
characteristic visibly changes the shade!

1.2.5. Fluorescent colours (P801C-P814C):

The PANTONE daylight fluorescent-colours are only to be produced with white pre- print, since the fluorescent effect
would otherwise be lost! (Fig 10)

In this range the blue P801C is the colour that has the least fluorescent effect.

Fig 10

1.2.6. Special colours (SC):

Special colours can be developed for clients with particular requirements (SC...). To a great extent these colours have
very specific features- / please consult Printing with these colours.

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Sony DADC Printing Process - Screen Print

1.2.7. Clear varnish:

The clear varnish is a transparent gloss varnish that, similar to a conventional offset-UV-varnish, intensifies the print
colours.
Especially offset prints, which make a tarnished impression because of their colour composition, can really be improved
with the following varnishes. (Fig 11)
The effect of the clear varnish is only given if smooth areas are overprinted. If for example a picture print or a pantone
screen area is overprinted with clear varnish, the result is an uneven basecoat, a kind of orange skin-effect that
influences the visual quality of the product.

with clear without clear

varnish varnish

Fig 11

1.2.8. Mattlack: (DXX-0998)

The matt varnish is a top coat that provides the product with a matt finish.
A very common combination for matt varnish is a design with glossy black on which matt varnished elements are
printed or in which elements are excluded, to achieve a matt/glossy contrast. (Fig 12)
If matt varnish is combined with clear varnish, the clear varnish is printed first. The matt varnish is then put on the clear
varnish. Reversing this order is not possible, because clear varnish on matt varnish loses its gloss.

Fig 12

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Sony DADC Printing Process - Screen Print / Offset

1.2.9. Sniffle colours:

Sniffle colours (= Fragrance colours) consist of the mat varnish DXX in which micro scent capsules are mixed in, which
open when in contact with friction and set free the enclosed scent.

1.2.10. Thermo varnish:

Thermo varnish (Thermo1) is a varnish option that can be printed with thermo printers (for example Prism print- Rimage).
This printable varnish is shiny and has a slightly sticky surface, because the varnish should not be completely hardened
through so it can be printed on better.
1.2.11. Inkjet varnish:
Inkjet varnishes have a water soluble surface, the ability to absorb inkjet ink. The surface from ink-jet discs is slightly
sticky like the thermo varnish.

1.3. Offset

- Offset printing is only possible for the colours Cyan, Magenta, Yellow and Black. Because these colours are
purchased in addition, no special colour mixing is possible.
- The offset print has the possibility, aside from the 4 CMYK colours, to print an extra PANTONE colour on the
first and on the last place.
For example: a white pre- print and at the end another effect with diverse varnishes or also a PANTONE colour.
In doing so the order is not variable (SD / CMYK / SD)!
- Furthermore it is important, that a certain fitting inaccuracy due to the different print procedures can occur,
when combining screen print and offset print.
- The offset print uses a lower full tone density. This effect is noticeable if one prints 100% black. If larger areas
are printed, problems develop because the black seems gray and staining and irregularities appear in the area.
This effect can be corrected by depositing the black with the other CMYK- colours. Ideal are the values 60%
Cyan, 40% Magenta, 40% Yellow und 100% Black! (Fig 13)
- The offset print is not suitable for the printing of large areas. In print a bar or staining could form. If a strong
bar is formed, someone should try and find another solution, because in such cases the clear varnish would
just enhance this effect. Here for example a PANTONE print would be recommended.

Fig 13

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Sony DADC Printing Process - Offset / Labelprint without white pre-printing

- The offset colours have a slightly matt surface. If the client does not wish this, one can improve the result with
clear varnish.
- A white pre-print is always recommended, unless the client wishes a metallic effect. Thereby one has to
consider that the colours change as well. (Fig 14 and 15)

Fig 14 with Wei Fig 15 without Wei

2. Label print without white pre-printing

- If a label is printed without a white base coat or with the separate white base, one has to pay attention that
the disc in the area between Spec. B and A has a barcode ring. (Fig 16 and 17) The visibility of the bar code
ring minimized with the white base.
This must be authorized by the client.

Fig 16 Fig 17

- The shining through of the disc silver changes the colour and does not correspond anymore with the PANTONE
colour guide. (See also1.2.1. Pantone colours)
As the different disc types (CD-R, DVD-R, AUDIO,..) have different shades of colour, the appearance of the
white base colour is changed by the reflexion characteristic.

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Sony DADC Disc variants / Tips & tricks

3. Disc variants

Aside from the different product types at Sony DADC, there are also different disc types:

- 12 cm Disc
This disc is printable with all specifications. The max. external diameter is 117mm.

- 8 cm Disc
It is printable for all specifications. The max. external diameter is 77mm.

- Dualdisc
The disc is printed on both sides and has a DVD (Side A- max. external diameter 43.5mm) and a CD (Side B-max.
external diameter 33.5mm).

- DVD 10
The disc is printed on both sides like the dual disc, but has 2 DVD sides (mostly PAL and NTSC). The standard
DVD10-H/A-STAND (External diameter 43.2mm) and DVD10-H/B-STAND (External diameter 35mm) or the
standard DVD10 RING/SPEC.G (max. external diameter 38.5mm) is used for the white pre- print.

- VinylCD
The Vinyl CD can be produced in the most various colours (Black, gold,..). The design can have an external
diameter of 54mm or 62mm. To achieve the vinyl effect, rings out of clear varnish (with a colour vinyl disc) or
Marabu Black (with black vinyl) are printed on the end. Vinyl discs can only be printed offset.

- Blu-Ray
A special white is used for the white pre-print (Colour description = BD- White). The Blu-Ray Disc can only be
printed in offset. Special varnishes and a separate white base are not possible. The Blu- Ray logo should only
have one colour or feature gray shades.

- Super Audio
The conventional white full base colour 117mm is used for the base.

4. Tips and tricks

4.1. Black on over prints

Since Black is a covering colour, it can be printed over the PANTONE colours. This is very helpful for printing if there
is a main text or a fine design in the design. When over printing there is the so called register impreciseness avoided.

Black should if possible be set to overprint, unless this is not possible for reasons of data transfer or it does not work
with the design. (This can also be used for P877C!)

4.2. When to use Marabu Black (#34) and when to use KNRC 65 (#54)
If a design predominantly consists of an area and the screened design is very simple, it is possible to expose the films
in #34, because with Marabu Black the area print turns out nicer. If the screen design, however, predominates or the
design is very fine or rather has different gradients, it must be printed in KNRC 65 with #54 to achieve an acceptable
result.

4.3. Offset Black only in 4C

To achieve the right Black in offset (mainly with areas), the Black should be built up with four colours in 60/40/40/100
(see also Fig 13)!! Exceptions are made for very fine texts and design elements, because smearing is not possible here.

4.4. Individual white base

The indivdual white base can have a max. interior diameter of 23.3mm (with Spec.F) and an external diameter of
116.7mm. White cannot be printed on PANTONE, because colour changes occur.

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Sony DADC Tips & tricks

4.5. Equal raster angle formation

If two screen areas are printed over each other in PANTONE colour (is allowed for exceptions- Duplex, if the client
wishes a colour change, or rather if the client was informed) it must be regarded that the raster angle is not
identical. Otherwise a strong Moire can emerge. The angle of Yellow, however, should not be used, because this
often also leads to a Moire.

4.6. Line width

When screen printing, the line width must at least have a thickness of 0.10 mm (positive) or 0.15 mm (negative).
Lines that are finer are excluded from the print.

4.7. Client proofs

If a client proof or a colour sample is enclosed, it gets compared with our proof- is there a deviation, CS must be
informed, because we do not pass on client proofs to the production. The client must either release our proof or
the data must be adjusted. The client proof or the colour sample, however, must be produced according to ISO
12647-7 with the corresponding profile ISO-Coated_v2. Only this way it can be warranted that the colours are
really displayed according to the data.

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 For further informationen:
Sony DADC
Sonystrasse, 20
5081 Anif/Salzburg, Austria
Graphicstudio

Sony DADC Global

Sony DADC Global
produziert ca. 2 Mrd. Discs pro Jahr und 100.000
Produces approx. 2 billion discs per year and 100,000
digitale Assets pro Tag mit einer digitalen
digital assets per day with a 2,000 terabyte digital
Speicherkapazitt von 2.000 Terabyte an den 16
storage capacity at its 14 production facilities located
Produktionsstandorten weltweit. Sony DADC hat ca.
world-wide. Sony DADC employs approximately
6.000 Beschftigte.
6.000 people.

Sony DADC Europa

Sony DADC Europe
produziert 600 Mio. Discs pro Jahr an den
Produces 600 million discs per year at its
Produktionsstandorten in Salzburg, sterreich und
production centres in Salzburg, Austria and
Southwater, UK. Betreibt 4 Logistik-Zentren (Spanien,
Southwater, UK, with 4 logistics centres (Spain,
Deutschland, Frankreich und Grobritannien) und
Germany, France, UK). With approximately 1,600
hat ca. 1.600 Beschftigte.
employees.

www.sonydadc.com
www.sonydadc.com