A system and method are provided for implementing a process by which printed rolls of substrate material web have additional material layers interleaved between the rolled material web layers to substantially eliminate back transfer or roll offset of printed images on the back sides of the rolled material substrates. In a process for pre-printing thermoforming grade plastic materials to produce rolls of substrate material for use in a thermoforming process, ink compositions, particularly adapted for the thermoforming process, are deposited on substantially continuous webs of substrate material. The webs of substrate material are then re-rolled with separate layers of low surface energy substrate material interleaved between the layers of the printed substrate material in order to substantially eliminate imaging defects produced by back transfer of printed images on to the backs of layers of the printed substrate material stored in rolls.