Station 00 / Case Study

From file to floor.
No excuses.

60-inch wide-format heads. Four-color process on corrugated, vinyl, and rigid foam. Trade show booths, franchise rollouts, and agency production runs — delivered before the ink smell has left the last run.

Source File · RGB · 150 dpi
Original flat RGB artwork file at 150 dpi showing soft edges and unsaturated color
Press Sheet · CMYK · 300 dpi
Finished printed piece photographed at macro distance showing halftone rosettes and saturated CMYK colors

Production Run · Feb 2026

47,000 units.

72 hours.

Zero reprints.

Production Run · Feb 2026

47,000 units.72 hours.Zero reprints.
60″ Wide-Format HeadsFour-Color Process CMYKCorrugated · Vinyl · Rigid FoamSpot UV CoatingDie-Cut FinishingICC Profile Matching72-Hour ProductionTrade Show ReadyFranchise Rollouts60″ Wide-Format HeadsFour-Color Process CMYKCorrugated · Vinyl · Rigid FoamSpot UV CoatingDie-Cut FinishingICC Profile Matching72-Hour ProductionTrade Show ReadyFranchise Rollouts
Station 01 / Prepress

File diagnostics
before the first drop of ink.

Every file runs through a 23-point preflight before it touches a drum. Color mode, bleed, ink density, font embedding — flagged and resolved before your deadline clock starts. Most jobs clear in under 4 hours.

Preflight Report · Job #PX-2847

Color ModeCMYK (ISO Coated v2)
Resolution300 dpi @ 100%
Bleed0.125″ all edges
Embedded FontsAll fonts outlined
Ink DensityTAC ≤ 300%
Spot Colors0 unmatched Pantones
TransparencyFlattened, PDF/X-4
Image Links12 / 12 resolved
Status✓ APPROVED FOR PRESS — 3h 22m
Prepress color proofing setup showing color swatches and pantone fan on a light table

23

Preflight checks

4h

Avg. clearance

99.1%

First-pass rate

Free Resource

ICC Profile Pack

Calibrated profiles for our three press configurations — corrugated, vinyl gloss, and rigid foam. Drop them into Illustrator or InDesign and proof to our exact output.

Get the Profiles

Station 02 / Press

Engineering tolerances,
not approximations.

Two 60-inch EFI VUTEk heads running UV-cure and solvent simultaneously. Registration held to ±0.5mm across the full print width. Ink densities verified against ISO 12647-2 after every 500-sheet interval.

Ink Coverage · Current Run

Cyan78%
Magenta82%
Yellow91%
Key (Black)65%
TAC Total316% ← Flag: reduce K by 16%
Wide-format printing press head laying down four-color process ink on large substrate

Substrate Specifications

MaterialThick.InkFinish
Corrugated B-Flute3mmUV-CureMatte / Gloss
Calendered PVC Vinyl4milSolventMatte Lam / Gloss Lam
Sintra Rigid Foam PVC6mmUV-CureMatte / Spot-UV
Aluminum Composite3mmUV-CureGloss / Brushed
Gatorboard1/2″UV-CureMatte / Lam

Free Resource

Substrate Comparison Guide

Side-by-side durability, cost, and print-quality data for every substrate we run. Use it to spec the right material for indoor, outdoor, and backlit applications.

Get the Guide

Station 03 / Finishing

Every layer,
every edge, every coat.

Finishing is where production runs break down at other shops. Binding misalignment, coating fish-eye, die-cut burr — we've engineered those failure points out. Spot UV registration held to ±0.3mm. Die-cut repeatability within 0.5mm across 10,000-piece runs.

Cross-Section · Rigid Foam Panel

Matte Laminate

3mil over-laminate, anti-scratch

Spot UV Coating

Selective gloss on brand elements

CMYK Ink Layer

UV-cure four-color process

Primer / Adhesion

UV-reactive base coat

Substrate

Sintra 6mm rigid foam PVC

Finished print sheets with die-cut edges and spot UV coating showing light reflection

Turnaround Matrix

Standard

5–7 business days

No rush charge

Priority

3 business days

+18% per order

Rush

24–48 hours

+35% per order

Emergency

Same day*

Call to confirm capacity

±0.3mm

Spot UV reg.

0.5mm

Die-cut repeat

100%

QC inspection

3 AM

Proof approval

Free Resource

Turnaround Calculator

Input your quantity, substrate, and event date — get a production schedule with ship date, finishing time, and prepress window broken out by day.

Get the Calculator

Station 04 / Resources

The knowledge
before the ask.

Every resource below was built because a client asked the right question at the wrong time — 11 PM before a deadline. Download them now. Use them on every job.

Primary Download

The Print-Ready
File Checklist

23 preflight checks in a single PDF. Every field matches what our RIP sees when your file arrives. Designers use it before export. Marketers use it to brief vendors. Procurement uses it to audit proofs.

Color modeBleed & safe zoneFont handlingICC profilesInk density limitsTransparency flattening

PDF · 4 pages · Free

No sales cadence. One email with the file. Unsubscribe anytime.

Additional Resources

Prepress

ICC Profile Pack

Calibrated profiles for corrugated, vinyl gloss, and rigid foam. Drop into Illustrator or InDesign and soft-proof to our exact output before you send a file.

ZIP · 3 profiles · 2.1 MB

Press

Substrate Comparison Guide

Side-by-side durability, cost, and print-quality data for every material we run — indoor, outdoor, and backlit applications covered.

PDF · 12 pages · 4.8 MB

Finishing

Turnaround Calculator

Input quantity, substrate, and event date. Get a production schedule with ship date, finishing time, and prepress window broken out by day.

Interactive · No download required

Ready to run a job?

Send files or call. We pick up at 3 AM.