Print simulation

Print process simulation uses interactive simulation software to reproduce the operating conditions of complex multi-colour printing presses that often cost several million dollars. Simulators are available for different printing process technologies (Offset Sheetfed, Heatset and Coldset Web Offset; Flexographic and Gravure Packaging), includes their consumables (like inks, plates, paper and other substrates) and where pertinent, in-line packaging operations (such as folding, cutting, label creation).

Press operators get ‘hands-on’ experience in quality control and problem solving without the costs, dangers or unstructured training associated with learning on actual presses. A wide variety of printing conditions and problems are covered that are used for training, skills assessment, performance enhancement and process analysis. Simulation is a means of presenting infrequent problems before they happen so that they can be recognized when they do occur.^[1] Exercises can evaluate specific competencies and if they are used to solve problems.^[2] When possible, simulators training scenarios are linked to industry-standard curricula like PIA, the NAA (Newspaper Association of America) and the Flexographic Technical Association.^[3]

Typical systems include monitoring and cost analysis that allows the training process to correlate with versus the waste, cost and time on a ‘real’ press.^[4] The simulators can either be either connected to a press control console (like the 'cockpit' in a flight simulator) or run on standard micro computer hardware with single or multiple screens. Internet-based learning management systems now allow simulation exercises to be made in a one language/location and reviewed in another language by a training supervisor in a different location – what is traced is the interaction with the process, not the local name of the controls.^[5]

As of 2013^[update] it is estimated that over 2000 print simulators are installed worldwide (in 2013). Users include technical schools, universities, printing companies and their suppliers,^[6][7] who find that they cut costs, accelerate training time, and give a more thorough grounding in structured problem solving

Simulators from Sinapse are used alongside real presses in the EuroSkills and WorldSkills competitions to select the best printer.^[5][8] Simulation based training is well adapted for the learning habits of today's world ^[7]

In 2013 the print simulation cloud-based learning system (DLMS) won a PIA (Printing Industries of America) Intertech Award:^[9]
Language-independent, it automatically analysed and compares training results from different countries, in different languages.
This DLMS was used at worldskillsLeipzig 2013^[10] to analyze and compare results from contestants using simulators in 10+ languages.