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I deal with this location daily, and they do a great job. It probably helps that their building is 500' away. You're right Mike - people from WI ARE awesome...
A lot of times this is caused by the shadow being over a spot color. Converting the spot color to process works if you're able to still hit the color at the printer.
I got some bad info, and need two 36" x 48" 4mm coroplast signs (black copy) delivered for an event by tomorrow in Gilford, NH. Please contact me if you're interested!!
There are various reasons printing Pantone (spot) would cost less to print, but not in the digital world. Any other form of printing may be one screen or plate Pantone color vs. 4cp trying to hit a specific pms#.
Here's a way to save a lot of time over perf cutting your parts apart;
Add a crop or corner mark to your file (at the rip or in the file). Print however may up with 0.25" gutter between the parts. Kiss cut the sheet, and then trim out into same size rows of parts. Stack the sheets of rows...
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