FORME SERVICES

Forme Services

Please click here to show/hide the process requirements and guidelines for Forme Services

Process Requirements & Guidelines:

Please follow the following steps when planning for Forme Services:

State Requirements:

Clearly state your requirements selecting from the following:

A sample or samples (specify board type & thickness)
A sample prior to manufacture for approval
A film drawing with centre lines or corner lines
A graphics file emailed or supplied on disk

Supply Information:

By Printed Sheet: Supply clean, dry, flat printed sheet (unfolded)
By Film positive: Positive only, no negatives
By Electronic file:
- File must be vector line file (using x, y co-ordinates) only
- No graphics in files allowed (suppressed or otherwise)
- Files where graphics are included or suppressed only may incur additional clean up charges
- All files received will be considered print side unless otherwise advised on the file or in writing
- All files must include an overall XY dimension to ensure scaling is correcton import
- Prefer fax confirmation of A4 plot so omissions can be caught prior to manufacturing
- Check file types accepted with supplier
By Client sample:
- Supply original and any changes required
By Fax:
- Be very specific with exact measurements
- Including all lengths, widths, depths, radius, glue flaps, dust flaps, stepping, etc
- Include rule to rule or point to point measurements
Existing Formes:
- For alteration, re rule or repair including specific written details of requirements
Verbal Order:
- Previous Forme Number (if remake)
- Sample Number (if from sample)
- Solely verbal orders will not be accepted for any other items

Job Specifications:

Mandatory Information Checklist must be completed for all jobs.

Print side marked
Grip edge marked
Rules to be omitted marked (where you are guillotining)
Stripping rules or nicks marked
Rule heights for cut and crease advised (if not on file)
Whether you are using Channel Matrix
Punch sizes – nearest match available or specific size
TPI (Teeth Per Inch) of any perforating rules
Wood quantity required all around and at grip, e.g. minimum wood.
Multi-up quantity required (including any interlocking requests)
Board type and thickness to be cut (to determine crease height)
Whether job is self adhesive
Legible contact name of person responsible for the job (in case of queries)
Quote number and price (if job is quoted)

The following information can assist us in determining the best way of designing or manufacturing your forme:

Bleed allowances
Job run size
Other miscellaneous requirements specific to your job

Companion Formes

State whether any of the following are required:

Female Stripping Forme Required (advise areas)
Male Stripping Forme Required (advise areas)
Counters required

Notes:

With the wider use of computer files some complex or over-detailed files may require altering prior to manufacture. We will make only necessary changes in order to manufacture. Any major changes or suggestions for improvements will be discussed with clients prior to proceeding.

IMPORTANT NOTICE BEFORE USING FORMES

Prior to commencing printing please check that the product is correct and that it performs to your satisfaction. No liability will be accepted for claims of whatever nature and howsoever arising other than for the remanufacture of this product. Although the aim is to produce optimum products for our clients, errors infrequently occur. Should any fault be found with the product please contact the supplier immediately. To ensure performance and accuracy, return this forme to the supplier for re-ruling and when alterations are required.

Structural Design	Prototyping/Sampling	Forme Manufacture
Stripping Formes	Counters	Forme Cutting
Die Making	Die Cutting

Structural Design

The physical structure of a carton or package designed on CAD package, taking into account not only obvious characteristics such as colour and shape, but intrinsic factors like what type of material to use, and how to design the package so that it will function most efficiently in its end use.

Examples: Cartons, header cards, swing tickets, folders, stickers, mailers

Tips:

Include stocks such as self-adhesive, non-flute, flute, PVC and polypropylene.
Whilst there are some specific limitations to carton design, for the most part it is limited only to your imagination and budget.
Always contact your supplier for individual specifications.

Suppliers: CP Gluing, Pandoras Boxes, Precision Forme Cutting Pty Ltd

Prototyping/Sampling

The production of a sample according to a CAD file in the necessary stock usually for the purposes of client approval. Most samples these days are produced by automated sample makers.

Examples: Cartons, header cards, swing tickets, folders, stickers

Tips:

Quantity of samples is usually limited to 1 to 50 units as it is not generally cost effective to produce large runs in this manner.
Always contact your supplier for individual specifications.

Suppliers: CP Gluing, Pandoras Boxes, Precision Forme Cutting Pty Ltd

Forme Manufacture

Tooling templates which go on the presses to cut, crease and perforating the plain or pre printed stock in order to produce the finished packaging product.
A cutting or creasing rule is bent to the desired shape and mounted in timber to make a cutting forme.

Examples: Cutting, creasing and perforating formes

Tips:

Most larger manufacturers are automated and can make formes ranging in size from the small for cylinders to the very large for roller presses. Check the maximum size that the supplier can produce to ensure they can meet your requirements.
There are also limitations with respect to distances for double cuts. Check with your supplier for these distances before completing your art.
Always contact your supplier for individual specifications.

Suppliers: Alltab Australia, CP Gluing, Precision Forme Cutting Pty Ltd, H.F. Webb & Son Pty Ltd

Stripping Formes

Female and Male stripping formes are a compliment to the cutting forme and assist the stripping of waste product from the sheet.

Examples: Removing waste holes, slots, windows, etc. from cartons

Tips:

Always contact your supplier for individual specifications.

Suppliers: CP Gluing, Marvel Bookbinding & Printfinishing, Precision Forme Cutting Pty Ltd

Counters

They are plastic templates that are used in conjunction with the cutting forme to assist the creasing process.

Examples: Used generally on non-flute cartons.

Tips:

Counters are difficult to manufacture and require specific software and experience to master.
Always contact your supplier for individual specifications.

Suppliers: Alltab Australia, CP Gluing, Miracle Bookbinding,

Forme Cutting

Forme cutting is also described as diecutting.
It is a method of cutting and creasing paper or board to shape. It uses a cutting forme which is pressed into the stock by use of a press or die cutting machine.

Examples: Shape cutting, Stickers, cartons, folders, creased and perforated items

Tips:

Generally limited to paper, cardboard (flute and non-flute) and some plastics such as PVC and vinyl. Some suppliers may also cut gasket paper, cork and rubber.
Generally dense, thick and/or brittle products can not be cut.
Always contact your supplier for individual specifications.

Suppliers: Alforus, Alltab Australia, CP Gluing, Gumming & Varnishing, Heidelberg Australia, Marvel Bookbinding & Printfinishing, Melbourne Forme Cutting, Miracle Bookbinding, Pandoras Boxes, Precision Forme Cutting Pty Ltd,

Please click here to show/hide the process requirements and guidelines

The following standards apply to general forme cutting.

Styles:

General forme cutting of cartons, folders, CD’s, wallets and shapes
Creasing and perforating
Kiss cutting on self-adhesive and other materials

Sizes:

Heidelberg Minimums: 200 x 150mm
Heidelberg Maximums: 640 x 900mm
Flat Bed Minimums: 330 x 400mm
Flat Bed Maximums: 740 x 1040mm

Material:

Most trade forme cutters can run paper box board and flute from 70gsm up to B Flute. Sizes and stocks should be discussed directly with your supplier.

Cutting Formes

Formes can be produced from either film or file (refer to the Forme Services section for more information) There are three key steps to remember:

1. Mark the PRINT or OUTSIDE of the film.
2. Indicate the GRIP position.
3. Indicate the amount of grip i.e. 15mm.

Presentation

Lay corner must be indicated clearly
Sheets must be kept flat enough to run through the in-feed of most presses.
Pallets should be strapped and/or wrapped well enough to arrive to us without moving or falling from the pallet
Samples should always be provided in order for our operator to find position and compare relevant copy. As paper and board can shrink and expand in size it is not unusual for the fit or register across the sheet to vary.

As this is out of the print finisher’s control, bleeds need to be allowed for and tolerances should be discussed directly with your forme cutter prior to printing. Jobs printed as work and turn can cause two problems. It is not recommended that forme cutting and creasing is done from the back of the sheet or product, as this will adversely affect the accuracy of the fold on the crease. Further, guillotining the sheet in half prior to forme cutting will generally cause print to cut registration problems, depending on the job.

Always contact your supplier for individual specifications.