For anyone else reading this:
Stage 1
Content written, images decided (takes time)
Graphically Designed to Print Spec (takes time)
Sent to printers to print
Stage 2
Job details examined by an Estimator
Quote is generated for the Job
Stage 3 The Stage Most People Don't See
Printers have artwork room - File is processed by an Artworker
File internally proofed digitally on paper through RIP system (RIP = Raster Image Processor and costs a lot of money) - Takes Time
Changes noted by Qualified Proofreader
Changes confirmed by client
Changes input by Artworker
Final Proof sent to client
Proceed to Press
Stage 4
File is impositioned by a qualified person in Impositions using software (usually PREPS which is expensive but there are cheaper not as robust options)
Output is straight to plate (not many places use film then plate anymore)
Note: when files where produced through film, you needed a UV light and darkroom to transfer the image onto emulsified plate, this was an additional stage, plates need be washed and gummed, but before that you needed someone who could align all the film on to the plate and process it
Plates are checked by a qualified person who runs the Plate Making Machine
Plates are prepared and punched (some machines have automatic punching (like me) by this person who alights them to the printing room.
Stage 5
Plates are in 4's for full colour work, Cyan Plate, Magenta Plate, Yellow Plate, Black Plate. Each plate costs about £25 (might be a bit off been a while since I priced an individual or set of 4 -usually bought in bulk and stored in a dark room)
These are mounted on the printing machine by the "Press Man/Woman" - who then has to "makeready" the press machine, adjust for paper, humidity, ink wells, drying time, machine speed etc. and finally a colour press proof for the floor manager to examine in detail with a loupe (magnifying glass) to make sure the dots are perfect (yes dots!)
Once approved, which takes about 30 minutes (running up a £300 bill in that 30 minutes - yes machine time is expensive!), it is then set in motion. Usually for print runs it can be put on a 4 colour machine with perfecting (which means it prints both sides of sheet at the same time, and some places have 4, 8, 10, 12, 16 or 20 plate sections on their printing machine. Depending on the print run, you wouldn't put a Dl Leaflet of 10,000 on a B1 Printing Press with 20 plate sections. the job would be printed in about 1 minute. So that would be 30 minutes for makeready (£300 or more and then +1 minute just for that. It's more likely it would be put on a smaller printing machine with even 2 drums (plate sections) which would cost about £100 for the machine time. Alleviating your costs. But remember, if you have a print run of 1,000,000 and are thinking of saving a few bucks going a smaller machine you are incorrect. It would take much longer to print 1,000,000 full colour brochures on a 2 colour machine.
Anyway - once it's printed
Stage 6
It now needs to be trimmed to it's appropriate size.
A guillotine operator would then stack all the sheets and trim them as specified by the floor manager or by the Finishing Staff.
Stage 7
Folding Department -
It needs to be folded, either as saddle stitch for books up to 60 - 90 pages
Or it needs to perfect bound, for books that will have spines.
Either that or it's a flyer, or a poster or a dl leaflet - it needs to be trimmed, folded, and stapled etc.
Stage 8
Packaging
It's packaged and delivered to the customer.
Not only are there about 7 (possibly more) stages to getting the job from start to finish. There's a lot of people in the mix too.
Stage 1 - this is you and you make these decisions and work on this - that's a lot of your time and money.
Stage 2 - Involves 2 People: Sales Rep and an Estimator
Stage 3 - involves at least 3 people, Artworker, Proofreader and Manager
Stage 4 - Involves someone running impositions, and someone making plates - 2 more people
Stage 5 - Involves Press Men/Women usually big printing presses are run by 2 people
Stage 6 - Guilotine operator (another person)
Stage 7 - Folding department - usually run by 2 or more people
Stage 8 - Need to be packaged, shrinkwrapped, boxed or other
Not only are there about 14 people in the mix on this (there's a lot more by the way)
There's also all that machinery
Expertise of people running machines Or each stage of the process (4 years qualifying and years of experience)
There's also running costs of keeping a dark room, maintenace costs etc.
The list is endless.
When you think about it - you get a pretty good deal when you go to the printers.
Years of expert qualified hands tending to your every need.
Just don't ask for that job tomorrow lol
