Technical Information

In printing production, color consistency is a key metric for customer acceptance. However, even minor deviations in the workshop process can often lead to finished products that don’t meet color standards, resulting in returns or rework. From errors in ink mixing ratios and variations in substrate ink absorption, to fluctuations in ambient temperature and humidity, as well as inaccurate equipment calibration—these seemingly small variables can accumulate to cause noticeable color discrepancies.

In printing, color accuracy is crucial. However, achieving consistent colors can be challenging, often leading to color rejection during the printing process. Here are 7 common issues encountered in print shops that cause color rejection, along with strategies to avoid them.

1. Color perception varies from person to person. Did you know that color perception can differ from one individual to another? This variability may lead to disagreements about whether colors are accurate, potentially resulting in color mismatches during printing. To address this issue, it’s essential to use standardized color references and tools.

2. Environmental factors can affect color accuracy. Lighting conditions, temperature, and humidity all influence color fidelity. For instance, colors may appear different under natural light compared to artificial light. Maintaining a controlled environment in printing facilities helps minimize color variations.
3. The ink formulation plays a crucial role. The ink’s formula significantly affects color consistency. Variations in pigment concentration, viscosity, and drying time can lead to color changes. Using high-quality, consistent ink formulations is key to minimizing color variations during printing.

4. Changes in the substrate can lead to color shifts. Different substrates—such as paper, film, and others—absorb ink in distinct ways, resulting in variations in color appearance. It’s crucial to test and standardize your substrates to ensure consistent color reproduction across different materials.
5. Calibration of printing equipment is essential. Regularly calibrating printing devices is crucial for maintaining color accuracy. Over time, printers may drift from their original settings, leading to color shifts. Implementing a routine calibration schedule between annual certifications helps ensure consistent color reproduction.

6. Digital proofing reduces color rejection. Digital proofing (also known as soft proofing) lets you preview how colors will appear on the final print, thereby minimizing the likelihood of color rejections. By using digital proofs, you can identify and correct color issues before they even reach the printing stage.
7. Standardized procedures ensure consistency. Requiring everyone to use the same tools and follow identical processes can significantly reduce color waste in printing, guaranteeing consistent color quality across different substrates and production environments.

Establish reliable printing color standards

So, how can brands address the issue of color inconsistency in complex supply chains?

The key is transitioning from physical reference lines to digital color standards. By precisely measuring approved color targets and capturing their full-spectrum data, a digital standard is created. These digital data then serve as the authoritative reference—distributed to each supplier—to ensure accurate color formulations and effective quality control.

The benefits of digital color standards:

• Eliminated the variability of the physical guide plate
• Maintain color accuracy over time
• Achieve faster and more precise color formulations
• Ensure consistent communication among suppliers
• Reduce rework, waste, and production delays

Achieving Color Data Standardization Using CxF

The Color Exchange Format (CxF) is an ISO standard that outlines how color data should be stored and exchanged. Widely supported in modern color-production software, this standard ensures accurate color communication.

CxF provides a standardized method for storing and exchanging color data, while the Pantone Master Standard offers a globally recognized visual reference for color communication.

PantoneLIVE: The Achievable Color Standard, Ensuring Consistency

PantoneLIVE digital color standards introduce standardized guidelines that have been rigorously tested and validated to ensure consistent results across various printing conditions. These standards eliminate guesswork and prevent significant color variations among suppliers. PantoneLIVE colors are securely stored on cloud servers, accessible via a subscription service, and seamlessly integrate with a wide range of software tools throughout the supply chain.

Digital standards provide a clear and consistent method for defining colors, eliminating ambiguity and ensuring accuracy. The Pantone Master Library delivers cloud-based color consistency, while the PantoneLIVE-related standards set achievable targets for ink and printing environments. By implementing digital standards, the entire printing process becomes more precise and predictable, reducing error accumulation and guaranteeing brand color consistency across multiple regions.

Test colors using the correct equipment

When it comes to achieving precise and consistent color measurements, investing in a high-quality spectrophotometer is essential. Spectrophotometers are critical for color quality because they deliver repeatable and reliable data, ensuring that products meet stringent color standards. Whether you're involved in the manufacturing of durable goods, apparel, cosmetics, or building materials, the right spectrophotometer can make a significant difference by detecting even the tiniest color variations.

Here are ten compelling reasons for a desktop spectrophotometer:

1. Repeatable Performance: Customers appreciate the consistent performance of our instruments, which ensures reliable and accurate color measurements every time. This repeatability is crucial for maintaining quality control, as it guarantees that each color measurement is both precise and dependable. Such consistency helps minimize errors and significantly enhances the overall quality of your products.
2. Easy to Maintain: The Ci7000 Series is easier to maintain than any other desktop spherical spectrophotometer currently available on the market. This makes it a great choice when you’re considering an investment in a desktop spectrophotometer. Easy maintenance translates into less downtime and lower upkeep costs, which can significantly boost operational efficiency. This feature is especially beneficial for businesses that require their spectrophotometers to run continuously and reliably.
3. Comprehensive audit tracking: When used in conjunction with our industry-leading quality control software, our desktop workstations deliver an unprecedented level of audit traceability—crucial for swiftly and effectively addressing any color-related quality issues. The audit trail provides detailed records of all measurements and calibrations, ensuring transparency and full traceability. This is especially vital for industries that demand strict adherence to regulatory standards and quality assurance protocols.
4. Compatibility with software solutions: These spectrophotometers are compatible with a range of software solutions, including NetProfiler, Color iMatch, Color iQC, Textile Color Hub, and PANTORA, providing measurement flexibility and consistency throughout the product lifecycle—from design to final inspection. This seamless integration with existing systems enhances operational efficiency and enables more streamlined color management processes.
5. Designed with calibration in mind: Integration with NetProfiler ensures that these spectrophotometers are engineered from the ground up with calibration as a core design principle, enhancing both their performance and reliability. Regular calibration is essential for maintaining the accuracy of color measurements. By leveraging NetProfiler, users can effortlessly calibrate their spectrophotometers in real time, guaranteeing consistent performance while minimizing the risk of measurement errors.
6. Wide range of applications: They are perfectly suited for any application with stringent color requirements, including durable goods, apparel and textiles, construction materials, cosmetics, and more. These spectrophotometers can accurately measure the chromaticity of various materials and products, making them invaluable tools across industries—helping to ensure product quality and customer satisfaction.
7. Sustainability: Customers appreciate our desktop spectrophotometers and Color iMatch software for their ability to create efficient, sustainable color formulation workflows. By optimizing color recipes and minimizing waste, businesses can achieve their sustainability goals while maintaining high-quality standards. This not only benefits the environment but also enhances the company’s reputation and overall operational efficiency.
8. High-quality design and engineering: The exceptional design and engineering of the Ci7000 series ensure consistent and accurate color measurement. These spectrophotometers feature robust construction and cutting-edge technology, guaranteeing long-lasting performance and reliability—making them a valuable investment for any business.
9. Measuring Flexibility: Our benchtop spectrophotometers come with a variety of optional accessories and aperture plates, offering maximum measurement flexibility for diverse sample types and sizes. Whether you need to analyze small samples—whether the port is facing upward or downward—these spectrophotometers can easily meet all your requirements, making them a versatile tool suitable for a wide range of applications.
10. First-class service and maintenance programs: X-Rite offers top-tier service and maintenance plans specifically designed for spectrophotometers, setting a key differentiator from its competitors. With comprehensive service plans, users can ensure their spectrophotometers always operate at peak performance, minimizing downtime and maximizing productivity. ​​​​​​​​​​​​​​​​​​​​​​​​​​​​