Density Drifts?
Conventional drawdowns are effective for providing an example of a target printing color. However, brand owners also know that, with high-speed printing, there will be some variation.
Defining a Delta E tolerance is the common approach to setting expectations. Many brands use 2 dE00 (Delta E 2000) as a tolerance—But what does that look like? The best and worst answer a printer can offer a brand about an unacceptable printed color is: “It’s in tolerance.”
A digital color card displays an accurate visual example of the agreed target color, and it can also show the agreed color variation as a result of the tolerance. In other words, digital color cards can offer both the printer and brand an accurate visual representation of both the color target and the variation based on the allowed tolerance.
Using color cards, printers can truly set the visual expectation for the brand upstream—before going on press—including tolerance, streamlining the print production and approval process.
Tints & Print?
Conventional drawdown tools also cannot effectively simulate how tints will print in production. This is because conventional drawdown tools are expensive, and printers often do not have every variation of drawdown tooling to match their production tools.
In addition, producing color tints using conventional drawdown tools requires different procedures, with greater complexity, that create separate drawdowns for tints and the solid color.
With digital color cards, everything happens digitally, on the same card, with digital precision, in one click.
Repeat Ready, On-Demand
Consistent results with conventional analog drawdown tools are difficult to achieve. Even with skilled and experienced operators, variations in material batches can influence repeatability.
Digital color cards accurately illustrate the visual color and quality of a real ink on a real substrate—in about three minutes. The process particularly saves time if the ink kitchen needs to create many drawdown reprints. Color cards are produced using an inkjet printer, which eliminates complexity, reduces time (as much as 90 percent) and increases repeatability. Plus, they can be printed anywhere.
If a calibrated digital printer is on site at the brand or designer, the color card can even be printed remotely without shipping costs or time delays.
Color cards start with digital, spectral data that describes the color match. The final color match is typically measured and then saved into an electronic exchange file called a CxF (color exchange format).
Operators choose their CxF file and select a substrate they wish to simulate. Color cards can simulate standard materials or may be customized to simulate the printer’s specific substrates using a substrate measurement. Color cards can also be configured to simulate the real expected tint color values, as well as paper structure and dot gain. Because color cards are digital, it is easy to produce a single copy or many copies, on demand. Precision color management delivers accurate color—typically less than 1 Delta E.
A digital color card is not created on the same substrate as the production material and it is not varnished, but operators can use different color card media, such as glossy media, to illustrate both the color influence and appearance effects of a varnish or laminate. With many different types of print, digital color cards help to present clear expectations, drive consistent color reproduction and empower the supply chain to deliver faster, more accurate production print.
No further labor-intensive work is required to create a color card. Print how many you want, when you want. Color cards help to digitally transform more of the process—making it simpler, faster and more repeatable.
Edelmann Experience
Founded in 1913, the Edelmann Group is a family business with a long tradition. Its packaging experts are very much looking forward, rather than dwelling on the past. “It’s about challenges—But above all it’s about opportunities,” says Alexander Gaugenmaier, quality manager.
“Conventional production of ink drawdowns is very complex and, in truth, extremely expensive,” he comments. “There is a lot of manual work involved. First you create a color recipe based on the customer’s target color. The color is mixed in a small amount and printed on the original substrate. This color is then read with a measuring device.”
And, then, the process of creating an actual ink drawdown begins. In order to accurately communicate expected color results with clients, they create a proof on the original substrate, using a small printing machine specifically for this process.
“Unfortunately, the proof is not quite the color card,” continues Gaugenmaier. “We choose three samples with different ink densities from a number of proof sheets. An employee takes a template and cuts out small swatches by hand, varnishes them and glues them side by side on a card, the color card. Finally, labels are added.”
If the customer does not immediately agree with the color and the tolerances, they start all over again. This is, of course, very time consuming. Color approval can sometimes take much longer than everyone would like.
It’s not easy for someone who isn’t involved in this process to understand the complexity of it all. It’s just ink applied onto paper or cardboard—and then a whole series of manual steps. Archiving the cards is a project in itself.
When given the opportunity to invest in GMG ColorCard, a digital method of creating color references, Gaugenmaier was interested in trying it out. “The key is its ease of use. As soon as the measured value of the target color is available, central parameters, such as the printing process or substrate, are entered into the software.
The application has only one window, making it quick to use. With a final mouse click, accurate color cards are printed in a matter of minutes. “If we require more of these color cards, an employee in the ink kitchen just presses the print button. All data is archived,” he adds.
“Every spot color can be exactly reproduced—with unbeatable accuracy, in my opinion,” remarks Gaugenmaier. “If conventional color cards have been archived for years and are used again and again as a reference, color changes can never be completely ruled out. Digitally stored color cards don’t age. They can be accurately reproduced at any time.”
“Using color cards, printers have an accurate spot color visual for each combination of ink and substrate, even when using different print technologies.”
No Tedious Tasks
Other than artwork proofs set up by color management experts or done by trained, skilled personnel using sophisticated tools, ink drawdowns typically require manual work done by the experienced ink kitchen staff.
Today, the industry continues to face the challenge of finding trained operators to oversee all of these significant tasks. There is a shortage of well-educated and experienced people.
Simple, easy-to-use solutions eliminate production challenges and, concurrently, increase productivity without sacrificing quality. Technology like digital color cards can close this gap. As long as a spectral measurement of the recipe is taken, just about anyone can produce the color cards. Tedious tasks are eliminated.
Digital color cards ensure print results meet print buyer expectations, both on target and within specification tolerances. They are a true color reference—much more precise than a swatch book and more versatile than a conventional drawdown.
Digital color cards can also do things that conventional analog drawdowns can’t. With digital color cards, printers can easily illustrate color variation within spec—based on either density or color variation—and even illustrate functional qualities.
The digital process is a simple, focused solution that helps supply chain partners simplify the color communication process from start to finish. The result: better print, delivered faster. As demonstrated at Edelmann, it’s a new technological process that can deliver the accuracy that printers can provide and brands can work with.
About the Author
Previously, Levine was director of business development at the Color Management Group and worked with manufacturer partners, resellers and customers on strategic sales and marketing programs to improve business performance based around color technology products. Earlier, he held technical and sales roles of increasing responsibility at X-Rite Inc and at NUR Macroprinters.