Category: Blog

Joanne Hayes, a 24-year veteran of the publishing industry, started Simply Buckhead Magazine in 2010. She quickly developed the ‘must read’ magazine for the bustling metropolitan area of Atlanta. Over the years, Joanne and Walton Press worked closely together to develop a hybrid style publication specifically targeting her and her advertiser’s needs, using both coated and non-coated papers.

Joanne, how did you get started in publishing?

I started my career in retail sales in 1990, and while managing a clothing store in RI in 1996, was recruited by a customer to interview for a position to start the marketing for a new publication for the award-winning newspaper company, Southern RI Newspapers, in southern RI. I spent 12 years in advertising sales there, before being recruited to help start SO RI Magazine for another award-winning media company, Providence Media. I helped build a very successful advertising base there over 3 years, before moving to Atlanta. My specialty became starting things from scratch, and I parlayed that here in Atlanta.

What is Simply Buckhead Magazine?

Simply Buckhead is an upscale lifestyle magazine in Buckhead, Brookhaven, Dunwoody, Sandy Springs & Chamblee, distributed free in over 350 locations throughout the area eight times a year, plus online virtual reading, with over 103,000 monthly viewers. Simply Buckhead reaches tastemakers ages 24-65 who want to experience the best the area has to offer. From real estate and gardening, to local trends and dining, shopping and the arts, Simply Buckhead is the essential guide to living well in Atlanta, in the best area inside the perimeter.

Joanne, how did you get started in publishing?

I started my career in retail sales in 1990, and while managing a clothing store in RI in 1996, was recruited by a customer to interview for a position to start the marketing for a new publication for the award-winning newspaper company, Southern RI Newspapers, in southern RI. I spent 12 years in advertising sales there, before being recruited to help start SO RI Magazine for another award-winning media company, Providence Media. I helped build a very successful advertising base there over 3 years, before moving to Atlanta. My specialty became starting things from scratch, and I parlayed that here in Atlanta.

What is Simply Buckhead Magazine?

Simply Buckhead is an upscale lifestyle magazine in Buckhead, Brookhaven, Dunwoody, Sandy Springs & Chamblee, distributed free in over 350 locations throughout the area eight times a year, plus online virtual reading, with over 103,000 monthly viewers. Simply Buckhead reaches tastemakers ages 24-65 who want to experience the best the area has to offer. From real estate and gardening, to local trends and dining, shopping and the arts, Simply Buckhead is the essential guide to living well in Atlanta, in the best area inside the perimeter.

Why did you decide to use a combination of coated and non-coated papers?

The format is exactly the same as what we had in Rhode Island for SO RI magazine, and the reason it works so well here also is that the bigger clients who can afford a glossy/larger page will do so, for the premium positioning, and the lower rates we can offer for the non-coated paper allows many more local, independent businesses to be able to afford to advertise in the publication they need to be in most.  The non-coated paper we use is not newsprint, rather hi-brite white text stock, twice as heavy as newsprint, so the colors pop and clients are happy, without the expense of a glossy page.

What are some considerations as a publisher you would suggest to others considering this style of publication?

If you are in an upscale community looking to publish something sophisticated, approachable and relatable, and cater to smaller, independent businesses, along with the bigger box retail and services, this is the way to go.  There is an ad space that will be affordable for everyone.  I’d recommend no more than 55-60% advertising, and really focus on the quality of the editorial, which keeps our clients coming back every year.

About Simply Buckhead: 

Simply Buckhead reaches tastemakers ages 24-65 who want to experience the best the area has to offer. 24,000 free copies are distributed throughout the community eight times a year with distribution to more than 350 locations. The magazine format is unique to the Atlanta market with its oversized (10.5″ X 13.5″), glossy covers, and bright white text stock interior. It is sophisticated, yet approachable. Learn more at simplybuckhead.com.

About Walton Press: 

Walton Press is a full-service print house with services ranging from consultation and pre-press through printing and finishing. From bound glossy magazines to newsprint, Walton Press has the turn-key solutions for your every printing, advertising and distribution need. Walton Press is committed to excellence in quality, service and dependability. Contact us at waltonpress.com or by phone at: 800-354-0235.

Atlanta Business Chronicle is the #1 source of business news, market trends and opportunities within the Atlanta metro area. With over 40 years of partnership with Walton Press, Atlanta Business Chronicle speaks about integrity, success and evolution.

What are challenges the Atlanta Business Chronicle sees for publishers and printing in the future?

The media industry continues to evolve at a rapid pace, and our continued success hinges on our ability to stay ahead of the changing landscape. We believe that print will always play a role in what we do, but we do expect the Atlanta Business Chronicle print edition of tomorrow to look different than it does today. The greatest challenge we face is how to maintain a successful business model that balances the need for print content, digital content and a robust live event platform. The key to overcoming that challenge is using customer data and analytics to study our readers’ preferences and pivoting to reflect those changing behaviors. We have become much better at analyzing the needs of our readers and that has helped us grow our audience over the past few years.

Atlanta Business Chronicle and Walton Press have been printing and publishing partners for over 40 years. What is important to consider when choosing the right printing partner for long term success? 

Over our entire history with Walton Press, Walton has been a partner in every sense of the word. We could not have achieved the success we have without Walton’s consistency and professionalism. We know from talking to other business journals in our 40-publication family that not all printers are created the same. Walton Press truly understands and cares about our business, and when the time comes to move quickly and adapt, Walton Press is always there in lock-step with us. Atlanta Business Chronicle consistently ranks among the best among its peers when our company provides qualitative data on print quality, color and reproduction.

About Atlanta Business Chronicle: 

Atlanta Business Chronicle is a primary source of business news and information for the metro-Atlanta and Georgia business community with a mission to help our readers grow their businesses, advance their careers and simplify their professional lives. Our platforms include our weekly print edition, a robust digital presence – website, emails and social media – and an events platform that draws 8,000+ attendees annually. A publication of American City Business Journals, Atlanta Business Chronicle also offers our partners access to the 44 markets we serve nationally. Visit us at atlantabusinesschronicle.com to learn more and subscribe. 

About Walton Press: 

Walton Press is a full-service print house with services ranging from consultation and pre-press through printing and finishing. From bound glossy magazines to newsprint, Walton Press has the turn-key solutions for your every printing, advertising and distribution need. Walton Press is committed to excellence in quality, service and dependability. Contact us at waltonpress.com or by phone at: 800-354-0235.

Vice President of Print Solutions at Walton Press and 25-year print industry veteran speaks about keeping your options open in a turbulent market.

How did you get started in the print industry, and can you tell us about your career? 

I worked for a printing company while I was in college, and actually started in the bindery, sweeping floors and doing odd jobs. I finished school in 1992 with a degree in Printing Management, and then moved to Atlanta where I took a position as an Estimator for a large web/sheetfed company. After a couple of years I became restless and decided I wanted to pursue a career in Sales and Management. I’ve always had a passion for helping others as they faced their challenges in printing and business, and given my experience to that point it was a good fit. 25 years can go by quickly, and I’m still helping clients and enjoying it.

Print is alive and well. What leading factors are contributing to the growth of the print market in 2021 and beyond?

It’s heard often that the need for printing is declining, and in many areas that would be true. What never goes away I suppose is the need for communication. We all share ideas, news, products, services, fashion, music, you name it. So I’ve always thought of printing as another way to communicate, whether that be a magazine, postcard, an ad on the radio, a TV commercial, or a billboard sign. I believe a key to the growth in communication within the printing arena is using all the technologies available appropriately and the most efficient ways possible.

With an unprecedented paper market and supply chain challenges, what are factors do publishers need to consider when working with a printer? 

Keep an open mind, understand what printing options are available, and don’t be afraid to use them for what they can achieve. I think we all get locked into thought processes in which we believe things are a certain way now and must always be. I’m not sure if many publishers know how far some of the technologies have advanced in certain areas of printing that could completely change how they can use them. An example would be the high end color reproduction in coldset printing and non-glossy papers. Publishers may be amazed at the quality level that can be achieved and the cost savings available using this technology. Does a magazine have to be all glossy? Maybe not, hybrid publications that utilize gloss and non-gloss paper can be an extremely effective option for many publishers. Opportunities may be in front of publishers if they keep an open mind and embrace what is available to them.

What are the benefits of a ‘hybrid publication’ using a combination of coated and non-coated papers? 

Design flexibility and sales opportunity. Hybrid publications give the publisher the ability to offer levels of quality to their advertisers at different price points. Some advertisers may ask for a small, reasonably priced ad positioned on a lower profile page that would be ideal for the non-glossy pages within a hybrid publication. Other high end advertisers may be willing to pay for a 2 page centerspread glossy featured ad and would love to be in that exclusive position in the center of the magazine. Regional publishers could benefit greatly from this strategy, appealing to both types of advertisers. Another advantage could be increased circulation as a result of lower print prices per magazine. Instead of spending dollars on a smaller quantity for an all gloss magazine, publishers can take advantage of the reduced printing cost by adding to their quantity of magazines printed and distributed. Advertisers are attracted by a higher circulation

What are the biggest shifts you have experienced in your career?

Over my 25 year career the biggest changes in printing has been technology. Interestingly, the process of ink printing on paper is still very similar, the actual act of ink being transferred onto paper. But the introduction of computer technology in all areas around press production has had a tremendous impact on how printing is done today. Most processes within the print workflow are much faster: designing, file transfer, platemaking, proofing, scheduling, shipping are all areas that have been transformed from traditional methods to high speed, efficient processes. In addition, print quality has increased significantly with computer accuracy and improvements in equipment. I look forward to seeing advances in all areas and I’m sure I’ll continue to be amazed by what is possible.

About Walton Press: 

Walton Press is a full-service print house with services ranging from consultation and pre-press through printing and finishing. From bound glossy magazines to newsprint, Walton Press has the turn-key solutions for your every printing, advertising and distribution need. Walton Press is committed to excellence in quality, service and dependability. Contact us at waltonpress.com or by phone at: 800-354-0235.

SOLON, OH – May 28, 2024 – Graphco, the Exclusive Distributor for RMGT’s most popular 970, 920 and 790 offset presses throughout the Midwest and Southeast, is please to announce that an 8-UP+ RMGT 970PF-8+LED Long Perfector has been purchased by Monroe, GA based Walton Press. Scheduled for delivery in late July, this 38-inch press which features ASAP (Autonomous Smart Assist Printing) and LED instant-curing technology, will be showcased running live demonstration on the RMGT stand for the 11 days of drupe, the massive Global trade fair held every four years in Düsseldorf, Germany.

The 124-year-old company has roots planted firmly in long-run, heat-set and cold-set web-offset presses that produce in the range of 35,000 copies per hour. For smaller, lower-volume printing jobs, Walton Press has been using a top-of-the-line digital press for several years. However, as the demand for more short-run work continues to increase, technological limitations have impeded productivity. The ability to gang-run jobs is an attractive benefit of the RMGT. “We can run four up on a 25-by-38-inch sheet, compared to only one up now on our digital size sheet,” states Stuart Christian, President of Walton Press, sounding like a kid in a candy shop. “That’s a huge twist since our cost study shows runs as short as 500 sheets are actually produced on the new press more cost-effectively than on our digital.”

“We are excited to get back to offset for shorter print volumes, and of course at 15,000 4/4 sheets per hour the new RMGT meets our medium run length print volume as well,” declares Christian. Situated 45 miles east of Atlanta, the printing firm employs 100 full-time employees who produce a variety of magazines: from newsprint weeklies, such as the Atlanta Business Chronicle (circulation: 23,000), to glossy community titles like Simply Buckhead, an upscale, 96-page lifestyle publication for the ATL metro area (24,000 copies printed eight times per year). Walton operates two to three shifts, five days per week, in its 70,000-square-foot facility. “We run three shifts as needed, and our book of business has been quite large since the end of the pandemic,” Christian reports.

The management team considered investing in another heat-set web press, or a newer model ink-jet device, but decided against both options. The pushback on digital printing was easy to justify, according to Christian, who has been at Walton’s helm for nine years: “Walton Press has reached a pivot point between our high-quality web press [Manroland ROTOMAN] and the digital press [Kodak NexPress] that we are selling.

We feel the sheetfed offset from RMGT will take the [shorter] volumes at a much better price point,” he concludes. “We will also be much more competitive on runs under 20,000 with the sheetfed perfector speeding along at 15,000 sph [sheets per hour], printing double-sided. Ink jet would never meet our customer’s quality expectations, and of course the lower cost of equipment, consumables and traditional paper stock made the RMGT offset solution very attractive.”

In addition, Walton Press just upgraded their bindery with new high-speed saddle binders and perfect binders that will will use the same signature formats that their webs produce. This is another huge advantage to RMGT’s traditional 16-page, 32-page signature format in comparison with ink-jet which typically requires huge additional investments in non-traditional finishing equipment that is typically captive to the short lifespan ink jet machines.

Less paper and more work

Walton Press has opted to add a Quantum Design QRS-106 roll-to-sheet converter to its RMGT sheetfed press. “Adding the roll sheeter just makes sense for us to be able to use the same paper stock, which we buy a lot of now,” explains Christian. With the 970PF, “we also can vary the cutoffs, which we cannot do now,” he adds. The new machine will provide in- house equipment redundancy, “giving us more control to meet customer deadlines,” he says of production support.

The same model RMGT 970PF-8+LED press being exhibited at the PRINTING United Expo last fall in Atlanta caught the attention of Patrick Judge, Walton’s Managing Director of Operations. “It was the only sheetfed press I saw at the show and it really caught our attention,” he recalls. Due to the quick job turnarounds that are rapidly growing within their heat-set-web workflow, he was particularly interested in the LED instant curing component, which is essential to avoid bindery bottlenecks. Plus, the two energy-efficient, LED lamps draw only 75 amps of power in comparison to the Rotoman’s long heat-set tunnel. Faster make ready start-ups are another lure. “Right now, changeovers are our biggest setback,” Judge notes, “causing us to slow down production. And with the new press, we won’t be losing 500 sheets to get up to color.”

Analyzing the numbers, he estimates that Walton will save literally hundreds of tons of paper annually with the new 970PF-8+LED. “We expect to cut waste astronomically,” he says. Obviously, trucking in far fewer tractor-trailer loads of paper is huge from a sustainability standpoint. While acknowledging the RMGT’s attractive price point, Judge adds that substantial paper-waste savings enhance the return-on-investment (ROI) proposition for the new press.

Christian is confident that expanding the firm’s capabilities with the new 38” 4/4 long perfector will attract other types of customers and titles to Walton Press. “We’d like to expand our [product] line-up to include higher quality catalogs and magazines,” he shares, as well as organically enter new markets. For example, Walton presently outsources magazine components, such as inserts. “With this new press, we’ll be able to print and coat a couple hundred thousand high-quality inserts, in different versions, in-house every month rather than outsourcing. In addition, it can handle DAL [direct address label] cards for publishers,” he notes. These products represent entirely new revenue channels for the print service provider.

To help meet Walton customers’ demanding quality expectations, the RMGT press at drupa is demonstrating Autonomous Smart Assist Printing (ASAP), which deploys two cameras to control color, adjust registration and fully inspect every sheet. “This highly intelligent ASAP technology is becoming mainstream as we are now placing these intelligent cameras on many of our customer’s new presses,” believes Chris Manley, President of Graphco. “It brings the ability to evaluate every sheet, and then any non-compliant sheets containing even minute imperfections as small as 1 mm are removed them from the rest of the run. This goes for color fidelity as well, with a Delta E of .01 as the standard.” Judge likens such intense, quality-assurance measures to those seen on the high-speed, roll-to-roll flexographic presses that he employed earlier in his career.

“Graphco is honored to again partner with such a well-established and highly respected company like Walton Press. As we approach our 50th year in business I am more in awe than ever of companies like Walton at 124 years, and Advertisers Printing at 100 years young. Let’s face it, that’s a lot of payrolls to make in a row,” observes Manley, “And for this press to mark our second RMGT Long Perfector to include our roll-to-sheet device tells me that properly done offset printing for publication houses, and other web offset concerns, has a very long runway for sure. And no one can dispute the higher quality and lower cost of this technology versus inkjet, and web printers are accustomed to buying machines that last, so our incredibly durable RMGT platform is a big positive. We are excited to see this press running live in Dusseldorf, and then making its home back in Monroe, Georgia.”

About Graphco

Graphco is the industry’s leading provider of offset, digital and print finishing solutions. We proudly represent the finest brands of equipment including RMGT (Ryobi MHI Graphic Technology), SD-Italy, Foliant, Standard Horizon, Graphic Whizard, Petratto, Spiel Associates/Sterling, MBM, Kodak, Konica Minolta and many more. These brands are only as good as the technical support team that stands behind them, and Graphco’s reputation for top-notch service is second to none. Since 1976, Graphco has thrived in an ever-changing marketplace by loyally adhering to the firm’s original model for success: providing best-in-class print production equipment along with reliable and assured technical service. Learn more about Graphco at www.graphco.com, 800-458-2769.

Copyright 2024. All brand names are the property of their respective owners and may or may not be trademarked.

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Sheetfed and web offset printing represent two pillars of modern commercial printing, each tailored to specific project scopes and production demands. Sheetfed printing handles individual sheets of paper, feeding them one by one through printing units to deliver high-resolution output with precise color control. In contrast, web offset printing continuously draws from large rolls of paper—called webs—to achieve rapid production speeds and economies of scale on high-volume runs. Understanding how these methods diverge in paper handling, make-ready time, and overall print speed is crucial for marketers, publishers, and design firms aiming to optimize budget and turnaround without compromising quality.

Why Offset Printing services remain the industry standard

Offset Printing services excel by combining consistent output with versatile substrate options, making them the go-to solution for pieces ranging from art books to direct mail campaigns. This technology transfers ink from metal plates to a rubber blanket and then onto paper, yielding crisp text and vibrant images. Compared to digital alternatives, offset printing maintains cost-efficiency on medium to large runs, thanks to low per-unit expenses once the press is set up. Its ability to handle specialty inks, coatings, and textured stocks further enhances brand impact and ensures every piece stands out.

What is sheetfed printing and when is it ideal?

How sheetfed printing works

Sheetfed offset printing takes single sheets from a feeder, transfers ink via plates and blankets, then ejects the finished sheet toward folding and finishing units. The machine’s modular design allows multiple print units—often four to eight colors—to operate in series, making it possible to achieve complex, high-fidelity color processes. Short to medium print runs such as brochures, business cards, and specialty packaging benefit from this precision, since setup time remains relatively low and substrate flexibility is high.

Advantages of sheetfed printing

Sheetfed presses shine when image quality is paramount. Exacting registration and color consistency enable photographers, designers, and luxury brands to showcase artwork and photography with exceptional clarity. The technology also supports thicker stocks, textured finishes, and custom varnishes—ideal for invitations, premium catalogs, and limited-edition prints. Quick job changeovers further empower printers to manage diverse workloads efficiently, handling multiple small runs back to back with minimal downtime.

What is web offset printing and why choose it?

How web offset printing works

Web offset printing pulls a continuous paper roll into the press, printing on both sides at high speeds before cutting and folding the paper into finished sheets or assembled products. This uninterrupted feed makes it possible to print thousands of pages per minute, a feature that has cemented web offset’s role in producing newspapers, magazines, catalogs, and direct mail at scale.

Advantages of web offset printing

When volume, speed, and cost-efficiency are priorities, web offset prevails. High-speed production slashes unit costs, particularly on runs exceeding tens of thousands of copies. Its ability to integrate in-line finishing—such as cutting, folding, and saddle-stitching—further streamlines workflows and shortens lead times. Large runs of periodicals, booklets, and mass-market mailers lean on web offset’s rapid output to meet tight deadlines without sacrificing uniform color and registration.

How do print quality and consistency compare?

Print quality showdown

Sheetfed presses consistently deliver superior image sharpness and richer color density, thanks to their controlled sheet-by-sheet approach. Fine details, small text, and subtle gradients emerge cleaner, making this method ideal for premium collateral. Web offset presses have narrowed the quality gap through advanced dampening systems and closed-loop ink control, but the continuous paper feed can still introduce slight variances in registration and gloss levels.

Maintaining color consistency

Both methods can leverage modern closed-loop color control systems to monitor density and registration in real time. These automated feedback loops adjust ink keys, dampening solutions, and blanket pressure to correct deviations during the run. For brand-critical applications—like high-end catalogs or corporate reports—this technology ensures every sheet meets predefined color standards without requiring manual intervention.

What cost factors influence sheetfed vs web offset decisions?

Production cost models hinge on setup expenses, press runtime, and substrate waste. Sheetfed printing typically incurs lower setup charges for short runs, as plate changes and feed calibrations happen quickly. However, unit costs remain higher on large volumes, since each sheet demands individual handling and alignment. Conversely, web offset features higher initial setup costs—threading the web, aligning inline finishing, and balancing print towers—but achieves dramatic per-unit savings once the press hits its stride on long runs.

When should marketers choose sheetfed over web offset?

Projects that demand exceptional visual impact—such as luxury brochures, fine art reproductions, and specialty packaging—lean toward sheetfed printing. The ability to handle textured, heavy, or coated stocks without compromise on registration makes it the preferred option for brands seeking tactile engagement. Rapid job changeovers also benefit agencies juggling multiple small-batch assignments, allowing them to maintain agility without incurring significant downtime.

When is web offset the clear winner?

High-volume requirements, time-sensitive publishing, and mass-mail campaigns thrive on web offset’s relentless throughput. Publishers of periodicals or large catalogs depend on rolling deadlines, often needing five-figure or six-figure quantities in a single run. The continuous nature of the paper feed, combined with integrated finishing modules, reduces manual intervention and accelerates delivery to distribution channels.

How do RMGT and Rotoman presses compare?

RMGT vs Rotoman technology features

Robert Clarke presses from RMGT bring one-pass perfecting capabilities that print both sides of the sheet simultaneously, reducing make-ready waste and accelerating throughput. LED-curing modules on RMGT 9-Series machines enable instant ink drying for immediate finishing. By contrast, Rotoman presses excel in highly automated inline processes, featuring web tension controls and rapid web roll changes to optimize high-volume magazine or catalog production.

Side-by-side comparison

What about brochure vs catalog printing decisions?

Brochures and catalogs serve distinct marketing objectives even though both employ offset processes. Brochures are concise, folded pieces designed to spotlight one campaign, event, or product line. Their smaller footprint and folding options make them easy to distribute at trade shows or as inserts. Catalogs, on the other hand, present extensive product lists across multiple pages—ideal for retail and wholesale brands wanting comprehensive ordering guides.

Selecting the right format

For limited product lines or focused messaging, brochures deliver targeted impact without overwhelming readers. If a company offers diverse SKUs or detailed specifications, catalogs offer a deeper dive, encouraging cross-selling and repeat business. Catalog runs often justify web offset’s scale, whereas brochure runs may find sheetfed’s agility more cost-effective.

How do finishing and mailing integrations enhance value?

Coupling printing with finishing and distribution elevates operational efficiency and customer experience. In-line processes like UV coating, die-cutting, and folding streamline handoffs between print and finishing departments. Pairing printing operations with in house mailing services enables direct mail campaigns to bypass external handling, reducing transit time and errors while consolidating billing and tracking under a single provider.

How does closed-loop color control safeguard brand integrity?

Implementing automated feedback systems that measure density and registration on every sheet empowers printers to maintain brand-defined color tolerances. Continuous scanning of printed outputs allows immediate ink key and dampening adjustments, preventing color drift across a run. For multinational campaigns or time-sensitive product launches, this level of quality assurance underpins brand consistency and mitigates costly reprints.

Balancing speed, setup, and sustainability

Offset processes generate waste during make-ready and color proofs, but modern presses use reduced-energy motors, vegetable-based inks, and quick-cleanup mechanisms to lower environmental impact. Choosing between sheetfed and web offset involves weighing sustainability goals against production demands. Short runs favor sheetfed for lower waste volumes, while web offset on large runs benefits from per-unit waste amortization and in-line recycling systems that repurpose trimmings.

Conclusion: Aligning printing strategy with project goals

Selecting between sheetfed and web offset printing hinges on run length, quality requirements, turnaround, and budget. Sheetfed excels in color fidelity, substrate versatility, and short-run agility, while web offset triumphs in volume, speed, and cost-efficiency. By evaluating project specifications—whether luxury brochures, high-volume catalogs, or multimodal mailings—organizations can deploy the optimal printing solution. To leverage comprehensive Offset Printing services that balance technology, quality, and distribution, walton press provides end-to-end expertise. For tailored guidance and precise estimates, reach out to Contact Us and discover how Walton Press can fulfill your print and mailing needs.

Frequently Asked Questions

How do setup times differ between sheetfed and web offset printing?

Sheetfed setups typically require less time per job because they handle individual sheets and adjust color units independently. Web offset presses incur longer initial setup for web threading and in-line finishing calibration but gain speed advantages once running.

Can web offset handle specialty paper stocks?

Yes, many web offset lines now support coated, uncoated, and lightweight films. However, extremely thick or textured substrates may still be better suited to sheetfed equipment due to feeding limitations.

What is the minimum run length for cost-effective web offset printing?

Large web offset runs generally become cost-effective starting around 10,000 to 20,000 pages, depending on press configuration and paper costs. Below that threshold, sheetfed often offers better per-unit pricing.

How does color consistency compare across both methods?

Both sheetfed and web offset can achieve tight color tolerances using automated closed-loop color control. Sheetfed’s register stability gives it an edge on finer details, while web offset maintains remarkable consistency over extended runs.

Is one method more sustainable than the other?

Short-run sheetfed printing typically produces less total waste, whereas web offset maximizes efficiency on long runs by diluting setup waste across many units. Modern presses further reduce environmental impact through energy-saving drives and eco-friendly inks.

Closed-loop color control is an automated color management system that continuously measures printed output and adjusts ink settings in real time to maintain consistent hues across press runs. By integrating spectrophotometers, ink pre-setting software, and press console interfaces, this workflow reduces human error and minimizes color deviation. Printers implement closed-loop color control to uphold strict brand standards, ensuring that corporate logos and packaging reproduce identically regardless of shift or substrate variation. This proactive approach to color calibration enhances overall print quality while streamlining press operations.

How does closed-loop color control work?

Closed-loop color control marries several interdependent components into a self-correcting feedback loop. The process begins in the prepress department and ends on the press console, with data flowing seamlessly between each stage. resource center.

File conversion and ink pre-setting

During the plate-making process, RIP output generates both high-resolution plates and low-resolution files (such as CIP3 or 1-Bit TIFFs) destined for the closed-loop workflow. Ink pre-setting software reads these files, calculates required CMYK ink coverage, and translates that into specific ink key settings. This automatic conversion cuts makeready time significantly, giving operators a precise starting point for color density.

Automated scanning with spectrophotometer

An integrated scanning spectrophotometer glides over a designated color bar on each sheet, capturing L*a*b* values for every ink zone. By comparing these measurements against predefined standards, the system identifies deviations in tint, hue, or density. This real-time data feeds back into the control software, priming the press for immediate corrections.

Feedback loop and continuous optimization

Once the spectrophotometer transmits measurement data, the management software calculates ink key adjustments and dispatches commands to the press console via a Direct Press Interface (DPI) or press-specific protocol. This closed feedback loop repeats at set intervals—often after every few sheets—ensuring that color drift, substrate changes, or operator variations never compromise brand integrity.

Components of a Closed-Loop Color Control System

Why is closed-loop color control crucial for brand consistency?

Brand consistency hinges on delivering identical color output across every marketing collateral, from high-end brochures to corrugated cartons. Without closed-loop systems, slight temperature shifts, substrate batch changes, or operator adjustments can introduce tonal variations that erode brand equity. Automated color control ensures each offset color accuracy checkpoint aligns with internationally recognized standards like ISO 12647 and G7. This tight regulatory adherence guarantees that a corporate blue on packaging in Lahore looks identical to the same blue printed in London or New York.

How do Offset Printing services benefit from closed-loop color control?

Offset Printing services unlock significant value when closed-loop systems are in place. By starting each job with pre-set ink keys and continuously monitoring color bars, printers slash makeready waste by up to 50 percent and reduce total press stops. This precision not only shortens job changeovers but also elevates print quality metrics such as dot gain consistency and color gamut reproduction. Clients experience uniformity across multi-part stationery, flexible packaging, and promotional materials, reinforcing brand trust and reducing costly reprints.

What role do print quality metrics play in closed-loop control?

Print quality metrics—such as density readings, gray balance values, and spectral deviation—drive the corrective algorithms at the heart of closed-loop color control. Density measurements ensure that total area coverage remains within specified tolerances; gray balance checks confirm neutral grays without unwanted color casts; and spectral data detects shifts invisible to the naked eye. By benchmarking against ICC profiles and proof standards, the system can predict and rectify color drift before it manifests on the client’s press sheet.

What technologies enable offset color accuracy?

Offset color accuracy depends on a suite of advanced technologies working in concert:

• Color bars embedded on each form for real-time density and tint readings
• Digital front ends (DFEs) that manage job tickets, color profiles, and screening
• G7 calibration workflows to align neutral density curves across devices
• Inline spectrophotometers for continuous L*a*b* measurement
• Automated ink key controls driven by feedback protocols

Together, these tools transform a traditional offset press into a precision instrument capable of replicating brand colors with surgical exactness.

How can print operators implement closed-loop control on the press?

Implementation begins with comprehensive setup: defining color bar layouts, entering ink zone counts, and uploading target density and L*a*b* data into the management software. Operators then run an initial calibration sheet, which the spectrophotometer reads to set baseline ink keys. Once the press is in motion, the software triggers scans at predetermined intervals, automatically adjusting the console’s ink keys to maintain the target values. Regular maintenance—such as cleaning sensors, verifying calibration standards, and updating ICC profiles—ensures the loop remains closed and the press consistently hits its color targets.

How to integrate closed-loop color control into existing workflows?

Integrating closed-loop color control requires collaboration between prepress, pressroom, and production planning teams. Prepress must export RIP data tailored for ink pre-setting, while pressroom staff needs training on spectrophotometer alignment and console interfaces. Scheduling should factor in initial calibration time and periodic verification runs. Enterprise resource planning (ERP) systems can pull job specs directly into DFEs, guaranteeing that color standards, substrate details, and workflow instructions travel with each job ticket. This holistic approach turns color control from a stand-alone solution into an embedded pillar of operational excellence.

How does closed-loop control reduce make-ready time and waste?

Closed-loop color control streamlines make-ready by automating the pre-press calibration and mid-run corrections that traditionally required manual densitometer checks. Press stops for density tuning become rare, freeing operators to focus on sheet delivery and job throughput.

What are the best practices for maintaining closed-loop systems?

Maintenance of closed-loop color control hinges on regular calibration of spectrophotometers, updating ICC profiles when changing substrates or ink brands, and verifying press console communication protocols. Shops should schedule monthly audits of color bar readings against certified calibration targets and recalibrate if deviations exceed 0.5 ΔE. Cleaning optical sensors, verifying plate quality in prepress, and controlling ambient pressroom humidity and temperature are also vital. Well-documented SOPs and consistent operator training ensure the system remains closed, responsive, and reliable.

How does closed-loop color control support value-added services?

While color fidelity is the headline, closed-loop color control also unlocks additional revenue streams. Accurate, repeatable color enables higher-value offerings like sequential numbering, variable data printing, and custom finishes without risk of misregistration. When paired with in house mailing services, printers can deliver perfectly matched direct mail campaigns that reinforce brand messaging down to the final envelope. These expanded capabilities build client loyalty and justify premium pricing.

Conclusion

Offset Printing services today face intense pressure to deliver flawless brand color across diverse print applications. Closed-loop color control answers that challenge by embedding continuous feedback, automated corrections, and industry-standard calibration into every press run. From file conversion and ink pre-setting through inline spectrophotometry and DPI-driven console adjustments, this end-to-end solution ensures offset color accuracy remains unwavering. For companies ready to elevate their print quality and brand consistency, walton press offers turnkey closed-loop solutions designed around each customer’s unique workflow. To explore how your operation can benefit, simply Contact Us.

Frequently Asked Questions

What is a closed-loop color control system?

A closed-loop color control system continuously measures printed output with a spectrophotometer and adjusts ink keys automatically to maintain target density and color values.

How does closed-loop color control improve print quality?

By automating color measurements and corrections, closed-loop control minimizes human error and reduces color drift, ensuring consistent print quality across long runs and multiple shifts.

Can closed-loop color control work on existing offset presses?

Yes. Most modern offset presses can interface with closed-loop systems via Direct Press Interface hardware or protocol emulation boxes, making retrofit possible without replacing core equipment.

What kind of ROI can printers expect from closed-loop systems?

Printers typically see 30–50 percent reductions in waste, 30 percent fewer press stops for color adjustments, and significant declines in reprints—often achieving full ROI within 12–18 months.

Are there industry standards for closed-loop color control?

Key standards include ISO 12647 for process printing, G7 calibration for gray balance, and ICC profile compliance for device characterization, all of which guide closed-loop system configuration.

In a world of fleeting digital messages, the tangible impact of a beautifully crafted print piece holds more power than ever. A high-quality catalog, a perfectly bound magazine, or a professionally finished mailer communicates permanence and authority.

For over 125 years, Walton Press has been the trusted partner for businesses that understand this power. This is not just a story about ink on paper; it’s a legacy of craftsmanship, reliability, and unwavering partnership in the world of commercial printing.

From our early days in 1898 to our modern, full-service facility today, our mission has remained the same: to deliver exceptional quality that helps our clients make a lasting impression. This post explores the core services that define our expertise and the principles that have guided us for more than a century. We will delve into what makes a premier commercial printing partner and how our comprehensive solutions in offset printing, bindery, finishing, and mailing services can elevate your brand.

The Art and Science of Offset Printing

At the heart of high-volume commercial printing lies offset printing, a method renowned for its superior quality, color consistency, and cost-effectiveness at scale. For projects like magazines, catalogs, brochures, and annual reports, there is no substitute for the rich, accurate, and consistent results that offset technology provides.

At Walton Press, we have honed our offset printing capabilities over decades. Our investment in state-of-the-art presses and our team’s deep expertise ensure every project benefits from:

• Unmatched Color Fidelity: We understand that brand colors must be precise. Our meticulous color management process guarantees that the colors in your design are the colors that appear on the final product, every single time.
• Crisp, Clean Results: Offset printing produces sharp lines and clear text, lending a professional and polished look to any document. This precision is critical for detailed product images in catalogs or sophisticated layouts in marketing materials.
• Efficiency for Large Runs: Once the initial plates are made, offset printing becomes exceptionally efficient for large quantities. This allows us to offer competitive pricing for high-volume projects without sacrificing quality, making it the ideal solution for businesses with significant print needs.

Our team works closely with clients, from designers to marketers, to ensure every file is optimized for the press. This collaborative approach minimizes errors and ensures the final output exceeds expectations, solidifying our role as a true print partner.

Precision in Every Detail: Bindery & Finishing Services

A print project isn’t complete when the ink dries. The final steps—bindery and finishing—are what transform printed sheets into a polished, professional product. These crucial services add durability, functionality, and a tactile quality that enhances the user experience. Rushing these final touches can undermine an otherwise flawless print job.

Our comprehensive in-house bindery and finishing department provides a wide range of options to perfect your project. By managing these services under one roof, we maintain strict quality control and ensure seamless transitions from printing to finishing.

Our key bindery and finishing services include:

• Perfect Binding: Ideal for catalogs, magazines, and soft-cover books, perfect binding provides a clean, flat spine that looks professional on any shelf.
• Saddle-Stitching: A cost-effective solution for booklets, brochures, and event programs, saddle-stitching uses staples to secure folded sheets along the spine.
• Coil and Wire-O Binding: Offering flexibility and the ability to lay flat, these binding methods are perfect for manuals, presentations, and notebooks.
• Cutting, Folding, and Trimming: Precision is paramount. Our automated equipment ensures every piece is cut to the exact specified dimensions for a uniform and clean final product.
• Coatings and Laminations: Add a protective layer and visual appeal with aqueous coatings, UV coatings, or laminations that can create a glossy, matte, or soft-touch effect.

These finishing touches are not afterthoughts; they are integral to the project’s success. Our experts provide guidance on the best options to achieve your desired look and feel while staying within budget

Bridging the Gap: Integrated Mailing Services

Printing a beautiful marketing piece is only half the battle. The other half is getting it into the hands of your target audience efficiently and cost-effectively. Walton Press offers integrated mailing services that streamline the entire process from printing to distribution, saving you time, money, and logistical headaches.

Managing a direct mail campaign involves complex postal regulations, data management, and coordination. Our dedicated mailing services team handles all of it for you, ensuring your materials are delivered on time and on budget.

Our mailing services include:

• List Management: We can process your mailing lists, remove duplicates, and ensure they meet USPS standards for maximum deliverability.
• Inkjet Addressing and Personalization: Add a personal touch with variable data printing, allowing you to customize names, addresses, and even promotional offers on each piece.
• Tabbing and Inserting: Our automated equipment securely tabs self-mailers to meet postal requirements and handles complex inserting jobs for multi-piece mailings.
• Postage Optimization: We work to secure the best possible postage rates for your project, leveraging our knowledge of USPS programs to reduce your overall campaign cost.

By integrating printing and mailing, we create a seamless, end-to-end workflow. This eliminates the need to coordinate between multiple vendors and reduces the risk of costly delays or errors.

The Walton Press Promise: A Partnership You Can Trust

For over 125 years, our name has been synonymous with reliability. In an industry where deadlines are critical and quality is non-negotiable, Walton Press stands as a beacon of stability. Our legacy is not just about our history; it’s about the trust we have built with generations of clients.

Our commitment to partnership means we function as an extension of your team. We provide proactive communication, expert guidance, and a problem-solving mindset to every project. We understand the challenges that businesses, publishers, and marketers face, and we are dedicated to providing solutions that make their jobs easier.

This philosophy, combined with our expertise in commercial printing, is what has sustained us for more than a century. We blend time-honored craftsmanship with modern technology to deliver print solutions that are not only beautiful but also effective.

Start Your Next Project with a Proven Partner

Whether you are producing a high-stakes marketing campaign, a quarterly magazine, or an essential company catalog, your choice of a printing partner matters. We invite you to experience the quality, reliability, and partnership that have defined Walton Press since 1898.

Let’s build something lasting together. Contact our team today to discuss your next project or request a sample kit to see our craftsmanship firsthand.