Inline Color Control for Flexo in Modern Printing

colorIn today’s fast-paced flexo printing environment, color accuracy isn’t just a desirable trait—it’s a non-negotiable necessity. Modern brands rely heavily on specific colors to communicate identity, ensure consistency across platforms, and build recognition with consumers. When it comes to print production, particularly at scale, even the smallest deviation in color can have outsized consequences. That’s where real-time inline color control for flexo steps in to revolutionize the color management process.

Color management in printing is the process of controlling and standardizing color representation across different jobs to ensure consistent and accurate color output. It is crucial for flexo printing because it ensures that the colors in the final printed product match the original design or intent, thereby maintaining brand integrity and meeting client expectations. Accurate color management helps avoid costly reprints and ensures that the printed materials reflect the intended vision effectively.

The Importance of Color Accuracy in Flexo Printing

Precision in color reproduction is a fundamental requirement for maintaining quality and consistency in printed materials. Whether it’s packaging, marketing collateral, or signage, accurate color ensures that the final product aligns with brand standards and customer expectations. The stakes are particularly high in industries like cosmetics, food and beverage, and pharmaceuticals, where brand colors are often tightly associated with the product’s identity.

To combat this, a robust color management system ensures that the colors designed on screen are faithfully reproduced on physical substrates—across different printers, substrates, and print conditions. Without this, the risk of mismatch grows, potentially damaging client relationships and increasing operational costs.

Impact of Color Variations on Brand Integrity

Consider a leading retail brand that has a signature shade of red. If that red prints too orange or too brown on packaging or advertisements, it can confuse consumers. Even slight shifts in color space can result in Delta E variations large enough to be noticeable to the human eye. This is where color management comes into play.

Maintaining strict control over color consistency is not just about aesthetics—it’s about protecting brand equity. In this context, effective color management becomes not only a technical requirement but a business imperative.

Challenges in Manual Color Monitoring

Manual color monitoring typically involves visual assessments or spot-checking printed samples with handheld spectrophotometers. While this method has been used for decades, it is fraught with issues. Human visual fatigue, inconsistent lighting, and subjective judgment all introduce variability.

Furthermore, manual checks are time-consuming, especially during long print runs. They interrupt workflows, and because they are reactive, they only catch color drift after it has occurred. By the time an error is discovered, a significant volume of defective prints may already be produced.

Understanding Real-Time Color Monitoring Systems

Real-time color management represents a dramatic shift from traditional quality control approaches. These systems are designed to detect and report color drift immediately during production, allowing operators to take corrective actions while the press is still running.

Instead of waiting for post-print inspection, real-time monitoring tools capture spectral data directly on the press, automatically comparing it to target values. This proactive approach allows for more precise control of color space and better color management overall.

How Inline Spectrophotometers Function

At the heart of most real-time monitoring systems is the inline spectrophotometer. These devices are mounted directly on press lines and scan every impression as it passes. They measure color with high precision, comparing results against defined targets in the chosen color space.

Techkon’s SpectroVision, for example, utilizes advanced inline spectrophotometry to provide continuous, high-speed measurements of color patches printed alongside jobs. When Delta-E drift exceeds tolerance thresholds, operators are alerted instantly, allowing for on-the-fly adjustments to ink densities or other parameters.

Integration with Existing Press Equipment

A common concern for print shops considering automation, such as color management, is whether new technologies will work with their existing equipment. Fortunately, companies like Techkon have engineered their solutions—such as the SpectroVision, SpectroEdge, and SpectroView—for seamless integration. Techkon’s inline systems were designed to interface with most leading offset and digital printers, allowing for retrofitting on older presses or immediate deployment on new ones.

Strategies to Minimize Delta E Drift During Live Printing

Minimizing Delta E drift—representing the difference between intended and actual color—during live printing involves several key strategies. Focusing on effective color management through the implementation of inline color control systems gives operators access to real-time color measurements, which reduces waste and helps with maintaining consistent color output.

Aside from inline solutions, other effective strategies to minimize Delta-E drift during live runs include:

“Closed loop” feedback systems: Adjust ink levels dynamically based on real-time data.

Techkon’s ChromaQA with SmartInk uses AI driven technology to remove the guesswork from toning ink on press. This technology brings us one step closer to actually adjusting colors on press automatically, while not being an entirely closed loop system. Overall, this system helps to increase billable work time, reduce wasted materials, and delivers consistent high-quality color.

Controlled environmental conditions: Temperature and humidity can impact how ink interacts with substrates.

Robust calibration and profiling: More effective color management can be guaranteed with regularly updated devices.

When combined with Techkon’s inline solutions, these strategies create a proactive system that dramatically improves color management and reduces production risks.

Implementing Inline Color Control for flexo Systems

When it comes to implementing inline color control for flexo systems, it is important to think about logistics of installation. Inline color measurement systems can be integrated into existing production lines, however, 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.

Utilizing Predictive Analytics for Proactive Adjustments

As more data is collected during press runs, modern color management systems can use predictive analytics to identify patterns and anticipate issues before they occur. This approach moves the operation from reactive to predictive, improving long-term consistency and minimizing downtime.

Regular Maintenance and Calibration of Equipment

Like any precision instrument, printers and spectrophotometers require regular upkeep. There are two types of calibration that Techkon’s devices must undergo. The first is a field calibration, in which the inline device will be calibrated each day using a small white tile that is built into the system. The second type of calibration is 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 provided a loaner device during this routine calibration.

Benefits of Real-Time Monitoring in Maintaining Target Tolerances

Real-time monitoring allows printers to maintain tight color tolerances throughout the entire print run. This precision helps avoid costly reruns and rejections by catching deviations early and correcting them immediately.

By maintaining a consistent color space, these systems uphold quality expectations and keep jobs on schedule. The result is happier clients, fewer errors, and improved operational efficiency.

Continuous Quality Assurance Without Production Interruptions

One of the most compelling benefits of real-time inline systems is their ability to provide ongoing quality checks without halting the press. Operators can see color readings live on-screen, reducing the need for stoppages to perform manual assessments. By decreasing the amount of material wasted on press and reducing make ready times, a company’s Return On Investment (ROI) can be improved significantly.

This uninterrupted quality assurance not only maintains print consistency, but also significantly increases throughput—an invaluable advantage in high-volume environments.

Reduction in Waste and Rework

By identifying color inconsistencies early, real-time monitoring prevents large quantities of defective prints from reaching the finishing stage. This reduction in waste saves money on materials, ink, and labor, while also supporting sustainability goals.

Rework, which often requires reprinting entire jobs, can be minimized or eliminated with consistent, automated color management.

Enhanced Efficiency and Throughput

Automation in color management translates to greater efficiency. With real-time systems handling measurements and corrections, operators can focus on overall workflow and performance. Make-ready times are reduced, job changes are smoother, and production speeds increase.

This enhanced throughput is especially important in just-in-time environments, where delays can affect entire supply chains.

Implementing Real-Time Monitoring for Inline Color Control for flexo Printing

Deploying a real-time system begins with assessing the current color management process and identifying weaknesses. For many printers, the transition involves retrofitting existing presses with inline spectrophotometers.

The benefits far outweigh the investment. With support from vendors like Techkon, implementation can be streamlined with minimal disruption to operations.

Selecting the Right Monitoring Technology

SpectroVision: Techkon offers several solutions for inline color control for flexo, digital, and offset web printers. Techkon’s SpectroVision is an inline color measurement system that is built for any flexo, digital, and offset web printer. This inline system offers real-time color measurement results while at full press production speeds. The SpectroVision can even measure an entire color bar in a single printed impression.

SpectroView: Techkon’s other inline solutions include the SpectroView, which is designed for industrial manufacturing settings. This inline solution is designed for anywhere color accuracy and consistency are critical, such as when working with extruded films and plastics, industrial coatings, powder coatings, and coil coatings. The SpectroView, like other inline solutions, measures color in real-time and has the ability to alert the operator when the color drifts out of tolerance.

SpectroEdge: Techkon’s third inline solution is the SpectroEdge. The SpectroEdge was designed as an OEM system that is to be included inside digital presses. This inline system utilizes an ES7500 spectrophotometer, which has the option to include a traverse arm.

Training Staff for Optimal Use

Technology is only as effective as the people using it. Training your team on how to interpret color data, operate the system, and troubleshoot issues is essential for maximizing ROI.

Ongoing education helps foster a culture of quality and continuous improvement in color management. Techkon offers hands-on training and support to ensure that all operators and technicians feel comfortable and confident with their updated printing process.

Analyzing Data for Continuous Improvement

The real value of real-time systems lies in their data. Over time, the collected metrics form a robust foundation for performance analysis. This allows teams to fine-tune press behavior, optimize ink usage, and improve operator performance.

Regular reviews of this data support process improvements and help refine the color management system continuously.

Embracing Innovation for Color Management in Flexo Printing

Staying ahead in today’s print industry means embracing the tools that ensure consistency, reduce waste, and deliver results. Real-time inline color control isn’t just an upgrade—it’s a necessary evolution in professional color management.

From predictive analytics to fully automated systems, innovative solutions from companies like Techkon empower printers to deliver exceptional quality with every run. As brands demand more precision and consumers expect perfect presentation, investing in smart color management technologies will separate the leaders from the rest. For more information, visit our website.