Inline Color Measurement for Printing Accuracy

In the fast-paced world of print production, maintaining consistent color quality is paramount. Techkon USA offers advanced solutions that ensure color accuracy and consistency throughout the production process. These solutions utilize sophisticated non-contact spectrophotometer technology combined with powerful software to deliver reliable results across a variety of paper substrates.

Inline Color Measurement and Control

Inline color measurement solutions offer a type of control that other spectrophotometers don’t have. These systems provide real-time color data from the integrated color sensor that helps press operators remain in control during every step of the printing process. This includes managing the effects of varying light sources.

Why Real-Time Color Accuracy Matters

Real-time color accuracy reduces waste and ensures that the final product meets exact specifications. Immediate feedback allows for on-the-fly adjustments, maintaining consistent color reproduction throughout the production run and quickly compensating for any unexpected color changes caused by fluctuations in light sources or liquid interaction with the paper or other printed material.

Industries That Rely on Precise Color Control

Several industries depend on precise color control, including:

Packaging and Printing: Ensuring brand colors are consistent across different materials and print runs on various types of paper or printed materials.

Textiles: Maintaining color consistency in fabrics and garments.

Automotive: Matching paint colors and interior materials.

Consumer Electronics: Ensuring uniformity in product appearances through advanced color sensor technology.

Techkon’s inline measurement systems are designed to meet the firm color requirements of these industries using reliable non-contact spectrophotometer hardware combined with intuitive software.

How Inline Color Measurement Systems Work

Inline color measurement is a process used in printing to continuously monitor and control the color consistency of products while they are on press. It involves using color sensors or non-contact spectrophotometers that are integrated into the production line to capture color data in real-time. This technology helps ensure that products meet specified color standards by immediately detecting any deviations and allowing for quick adjustments, especially important when dealing with materials such as absorbent paper.

The Role of Inline Sensors and Measurement Devices

Inline sensors, such as non-contact spectrophotometers, are integrated directly into the production line. These devices continuously monitor color, capturing data on color density, Delta E, and other critical metrics. By providing real-time feedback, they enable immediate adjustments, ensuring consistent color quality throughout the production run.

Feeding Data to Automated Correction Tools

The data collected by inline color sensors is fed into automated correction tools that analyze the information and make necessary adjustments. This seamless integration ensures that any deviations or color changes from the desired color standards are promptly corrected, maintaining consistent quality throughout the production run.

Closed-Loop Color Control Systems Explained

Closed-loop color control systems refer to the continuous process of measuring color output, comparing it to desired standards, and making necessary adjustments in real-time. This loop ensures that any deviations from the target color are promptly corrected, maintaining consistent quality throughout the production run. While traditional methods like spectrophotometers provide high precision in controlled settings, inline devices excel in providing continuous, consistent measurements during the production process. Techkon offers several inline solutions, including the SpectroVision, SpectroView, and SpectroEdge, which use advanced software and color sensor technology for superior results.

Core Technologies Behind Inline Color Measurement

In terms of inline color measurement solutions, Techkon has several options. Techkon’s SpectroView, SpectroVision, and SpectorEdge have been designed to meet the needs of a range of printing processes and materials, including various paper types, while accounting for the influence of different light sources.

SpectroView

SpectroView is Techkon’s inline non-contact spectrophotometer designed for industrial applications. Its measurement process is fully automated and provides real-time color measurements, creating a more repeatable manufacturing process, increasing the quality of manufactured goods, decreasing waste, and ultimately improving profitability.

SpectroVision

SpectroVision is an inline quality assurance solution that combines spectral-based color measurement, web viewing, and ISO/ANSI style bar code grading into a single product. Operating at press speeds up to 1,000 ft/min, it provides real-time feedback, eliminating the need for stopping and restarting the press for offline measurements and adjustments.

SpectroEdge

SpectroEdge is designed for digital and flexo presses, measuring spectral color at speeds of up to 2,000 ft/min. Installed on a mechanical arm that traverses the web, it measures in both print and transverse directions, providing real-time color quality reporting for press operators.

Image Processing

Advanced image processing techniques are employed to analyze the data collected by inline non-contact spectrophotometers. These techniques enable precise color measurements, ensuring that any deviations from the desired standards are promptly identified and corrected.

Benefits of Inline Color Measurement

When compared to other color measurement systems, inline color measurement systems offer the benefit of real-time monitoring and control, ensuring consistent color quality during production processes. This leads to reduced waste, shorter make-ready times, improved efficiency, and enhanced product quality by detecting and correcting color variations immediately. Additionally, they help in maintaining brand standards and meeting customer expectations by providing precise color data throughout the production line using advanced software.

Consistent Color Accuracy Across Runs

Implementing inline color measurement systems ensures consistent color accuracy across different production runs. This consistency is crucial for maintaining brand integrity and meeting customer expectations.

Reduced Waste and Rework

Real-time color monitoring allows for immediate detection and correction of color deviations, significantly reducing waste and the need for rework. This efficiency leads to cost savings and improved profitability.

Faster Make-Ready and Improved Throughput

Inline color measurement systems streamline the make-ready process by providing immediate feedback, allowing for quicker adjustments. This efficiency results in improved throughput and increased production.

Challenges and Limitations

Techkon USA’s inline color measurement systems, such as SpectroVision and SpectroEdge, offer advanced features for real-time color monitoring and quality control. While it is important to consider the challenges that new technology may bring, such as environmental variation and maintenance, Techkon is a leader in the field when it comes to integration with older systems.

Sensor Calibration and Maintenance Needs

Regular calibration and maintenance of inline color sensors are essential to ensure accurate color measurements. There are two types of calibration that Techkon’s devices must undergo. The first is a field calibration, in which the device will be calibrated each day using a small white tile that is built into the system. The second type of calibration is a recertification and requires the device to be sent to Techkon USA in Danvers, MA. This calibration is free with the Planned Maintenance Program. Users will be sent a loaner device during this routine calibration.

Integration with Existing Legacy Systems

Inline color measurement systems can be integrated into existing production lines. These systems are designed to be flexible and adaptable, allowing for seamless incorporation into various stages of production without disrupting the workflow, thereby ensuring continuous monitoring and maintaining consistent color quality in real-time. This integration helps optimize production efficiency and product quality. Issues can arise when deciding where to install the inline device, as well as where the control panel is going to be located. Techkon’s inline solutions are compatible with a number of manufacturers, including Ryobi, Heidelberg, Komori, Mitsubishi, and Manroland.

Managing Environmental Variables (Lighting, Heat, Dust)

Environmental factors such as light sources and conditions, temperature fluctuations, and dust can affect the accuracy of color measurements. Implementing proper environmental controls is necessary to mitigate these effects, especially when liquid inks or coatings interact with the paper substrate.

Selecting the Right Inline Color Measurement System

Selecting the right inline color measurement system is crucial for achieving consistent, high-quality print results while optimizing production efficiency. Techkon offers advanced solutions tailored to meet the diverse needs of the printing industry, notably through their SpectroVision and SpectroEdge systems.

Factors to Consider

When selecting an inline solution to integrate into your printing process, it is important to consider several factors, such as material type, production speeds, as well as environmental conditions.

Type of Material

The material being printed on can influence the choice of an inline color measurement system. Different materials, such as foils, clear substrates, or plastic films, may require specific measurement techniques to ensure accurate color reproduction.

Speed of Production

The production speed of the printing press is a critical factor. The chosen inline color measurement system must be capable of operating effectively at the required speeds without compromising accuracy. Techkon’s inline non-contact spectrophotometers are scanning devices, so when the lamp turns on, the devices are collecting spectral color data at 3000 samples per second (Hz) whereas most of our competitors strobe their light sources to “capture” the color.

Environmental Conditions

Consideration of the production environment is essential. Factors such as temperature, humidity, and cleanliness can impact the performance of inline color measurement systems. Techkon’s inline solutions utilize a white light source and is positioned close to the substrate to limit the impact that environmental factors may have on the measurement. Techkon’s devices also function without the need for a vacuum to stabilize the substrate.

Future Trends in Inline Color Measurement

The future of inline color measurement is being shaped by advancements in automation, artificial intelligence, and real-time analytics. Techkon USA stands at the forefront of this evolution, introducing cutting-edge technologies that enhance color accuracy, streamline production, and promote sustainability in the printing industry.

Machine Learning for Predictive Adjustments

The integration of machine learning algorithms into inline color measurement systems is an emerging trend. These algorithms can predict potential color deviations and make proactive adjustments, enhancing color consistency and reducing waste.

Smarter Sensors and Adaptive Algorithms

Advancements in sensor technology and adaptive algorithms are leading to more intelligent inline color measurement systems. These systems can adapt to varying conditions and materials, providing more accurate and reliable color measurements.

Broader Adoption Across Packaging, Print, and Textiles

The benefits of inline color measurement are being recognized across various industries, leading to broader adoption. Packaging, print, and textile industries are increasingly implementing these systems to ensure consistent color quality and meet customer demands.

Print Smarter with In-Line Feedback Loop Color Correction

Implementing effective feedback loops for real-time inline color correction is essential for maintaining consistent color quality in print production. Techkon USA’s advanced solutions, including SpectroView, SpectroVision, SpectroEdge, and ChromaQA with SmartInk, provide the necessary tools to achieve this goal. By integrating these technologies, print professionals can ensure color accuracy, reduce waste, and improve overall efficiency. For more information about Techkon’s color measurement devices, visit our website.