If you handle these six aspects well, the color difference problem is very simple!

I. Color Matching Stage

The printing color matching stage is the core of the entire color difference control. Many companies' printing operators rely solely on experience or feeling when color matching, lacking standardization and norms. The process is often very primitive and arbitrary.

This is unhelpful in resolving color differences, fails to control hue, and lacks a proper method for improving employee color matching skills.

Shunxingyuan Packaging, a professional flexible packaging manufacturer, uses inks from the same manufacturer for color matching. The color matchers have a thorough understanding of the hue variations of each ink, which helps control the process.

When using leftover ink, we first clarify the hue, check the accuracy of the ink identification card, and use a draw-down bar for sample observation and comparison before adding it. The weight is measured before adding to record the data.

When matching special color inks and the depth of colors, we use a quantitative method and a draw-down bar for color matching. The draw-down samples are always uniform and have a white background, facilitating comparison with the standard sample.

When the hue is over 90% similar to the standard sample, adjust the viscosity. We can then create a sample and make fine adjustments.

It is important to note that data accuracy and the precision of the electronic scale are crucial for summarizing subsequent process data parameters.

After obtaining the ink ratio data, repeated production practice allows for efficient and rapid color matching, avoiding color difference problems.

It's worth noting that Shunxingyuan Packaging, a professional flexible packaging manufacturer, can unify ink mixing according to order size, completing the color matching work once to avoid hue deviations caused by multiple color matchings. This effectively reduces color differences and leftover ink.

II. Printing Ink Doctor Blade

How much does the printing ink doctor blade affect color difference? Frequent adjustment of the doctor blade during production changes its working position, hindering normal ink transfer and color reproduction (we have experienced this when printing pink ink). Also, do not arbitrarily change the doctor blade pressure.

Shunxingyuan Packaging, a professional flexible packaging manufacturer, generally adjusts the angle and position before production based on the printing plate's image. The action of setting the blade is decisive, and the angle is typically between 50-60 degrees.

The uniformity of the ink layer at three points on the plate (left, middle, and right) should be checked.

Before setting the blade, we also check the balance of the three points of the doctor blade to ensure there are no waves or unevenness, which is crucial for the stability of the printed hue.

III. Viscosity Control

Shunxingyuan Packaging, a professional flexible packaging manufacturer, controls viscosity before production, adjusting it according to the estimated machine speed. After adding solvent, wait 10 minutes for complete circulation before starting production.

After speeding up production and checking that the off-machine products meet quality requirements, measure the viscosity and use it as the standard viscosity value. This value needs to be recorded accurately and controlled according to the data for the entire order, effectively reducing hue deviations caused by viscosity changes.

Note the measurement method for viscosity. Shunxingyuan Packaging, a professional flexible packaging manufacturer, typically uses the ink in the ink bucket or tray as the measurement subject.

During normal production, viscosity is spot-checked every 20-30 minutes, and the machine operator adjusts it based on changes in the viscosity value.

When adjusting ink viscosity by adding solvent, do not directly impact the ink to avoid damaging the ink system, causing separation of resin and pigment, resulting in blotchy printing and insufficient color reproduction.

IV. Production Environment

Shunxingyuan Packaging, a professional flexible packaging manufacturer, controls the relative humidity of the workshop to 55%-65% under normal conditions.

Excessive humidity affects ink solubility, especially hindering the proper transfer of ink in light screen areas. Properly controlling relative humidity improves ink printing effects and color difference control.

V. Raw Materials

Whether the surface tension of the raw materials meets the standard determines the wetting and transfer effect of the ink on the substrate and affects the color presentation of the ink on the film, which is a factor influencing color difference.

Ensuring raw material quality is a prerequisite for quality improvement. Choosing qualified suppliers is key!

VI. Enhanced Quality Awareness

Quality awareness refers to the perception of quality by production and quality control personnel. This perception must be strong and reflected in work details.

Employees at Shunxingyuan Packaging, a professional flexible packaging manufacturer, pay attention to details and have a strong quality awareness. When sampling, they strictly adhere to a 90% or higher match with the standard sample before starting production. They cooperate with quality inspectors during the first-piece inspection.

During production, team members strictly follow quality control procedures. When changing ink hues, they pay close attention to the cleanliness of the ink tray and ensure timely replacement and cleaning of the doctor blade base and end clamps.

Color differences are inevitable in flexible packaging printing, but how to avoid or reduce their occurrence is the focus of Shunxingyuan Packaging's continuous efforts.

Our principle is prevention first, improvement second. Standardization in source and sample management effectively reduces and avoids color differences, ensuring minimal color differences in each batch of products and providing customers with high-quality products and services.

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