ENSURING CONSISTENT COLOUR QUALITY IN DIGITAL PRINTING

In the ever-evolving world of digital printing, maintaining consistent colour quality is critical. Be it in wide format, packaging, textiles or any other application area, achieving and maintaining colour consistency is crucial to brand integrity, customer satisfaction and overall product quality. Achieving colour consistency, however, is no small feat. Several challenges can lead to colour variations, making it essential for print providers to be aware of and proactively manage these variables.

Environmental factors, such as temperature and humidity, can have a significant impact on colour quality in digital printing. Changes in temperature can alter the viscosity of the ink, affecting how it spreads and adheres to the substrate. For example, higher temperatures can make ink more fluid, causing it to spread more than desired, while lower temperatures can thicken ink, resulting in inadequate coverage.

Humidity also plays an important role. High humidity may cause substrates – especially paper-based – to absorb moisture. This will change its surface properties and cause colour shifts as the ink interacts differently with the substrate. Conversely, low humidity can cause the ink to dry too quickly, which may not allow it to fully integrate with the substrate. Maintaining a controlled environment in the printing facility is essential to mitigate these issues.

In any digital printer, the printhead is a critical component that directly affects the accuracy and consistency of colour output. Over time, printheads experience wear and tear that can result in nozzle clogging, misfiring or uneven ink distribution. The life of a printhead depends on the frequency of its use, the types of inks used and maintenance practices.

Regular maintenance – including cleaning and calibration – is critical to prolonging printhead life and ensuring consistent performance. In addition, timely replacement of worn printheads is necessary to maintain optimal colour accuracy and avoid production disruptions.

Fingerprint Technology takes colour management a step further

Varying ink and substrate conditions are another major challenge in achieving consistent colour quality. Different production batches of ink may have slight variations in their chemical composition, resulting in different colour output. Even small variations can cause noticeable discrepancies, especially in high-precision applications.

Similarly, substrates can vary in properties due to differences in manufacturing processes, storage conditions and handling. For example, paper substrates can have different degrees of whiteness, texture and moisture content, all of which can affect how the ink interacts with the surface.

To minimise these issues, it is important to source inks and substrates from reliable suppliers with stringent quality control measures. Consistent storage conditions, such as maintaining optimal temperature and humidity levels, can also help reduce variability and ensure consistent print results.

The conditions of the printing process can also have a significant impact on colour quality. Prepress treatments, such as priming, coating and corona treatment, prepare the substrate to receive ink evenly. Any inconsistencies may lead to uneven ink absorption and colour variations. For example, a poorly applied primer can cause areas of the substrate to repel ink – resulting in lighter or inconsistent colour patches.

Post-processing conditions such as drying, curing and heating, are equally important. Insufficient drying or curing, for example, can cause colours to bleed or change over time as the ink continues to interact with the substrate. 

Ensuring that all pre- and post-processing conditions are carefully controlled and standardised, is critical to maintaining consistent colour quality. This includes using the correct settings for each substrate and ink type, as well as monitoring and adjusting process parameters as needed.

Each of these challenges can introduce small variations in colour. While these individual deviations may be minimal, their cumulative effect can result in significant colour inconsistencies. Over time, if not carefully managed, the variations can grow and severely affect the quality and consistency of the printed output.

It is therefore essential to keep every aspect of the printing process under control. Regular monitoring, maintenance and calibration are key practices to ensure that all variables are kept within acceptable tolerances. In this way, print providers can minimise the risk of colour variation and maintain high quality standards for their products.

ColorGATE offers a comprehensive suite of tools to help digital printers meet these challenges and maintain precise colour control. Outstanding features of the ColorGATE Productionserver are Media Device Synchronization and Fingerprint Technology, as well as the Color Correction Loop Module.

Media Device Synchronization

Media Device Synchronization recalibrates the printer to the original profiling state. This is particularly useful because it ensures that any changes in the printing environment, printhead wear or other variables, are accounted for, restoring the printer’s colour output to its original standard. Recalibration is essential to counteract the drift in colour output that occurs due to wear and environmental changes, enabling printers to consistently produce high-quality prints.

Fingerprint Technology

Fingerprint Technology takes colour management a step further by creating a file that contains all the production steps of the original design. This file can be saved and reused for later runs or even for distributed production, ensuring that colours remain consistent – regardless of where or when printing takes place.

Color Correction Loop Module

For digital-print companies looking to expand their colour-matching capabilities, the Color Correction Loop Module works in harmony with the Fingerprint Technology. Using the created Fingerprint file, this module can automatically correct colour deviations during production. This continuous correction ensures that minor colour shifts are addressed immediately, maintaining the highest colour accuracy throughout the run. 

In the competitive field of digital printing, maintaining consistent colour quality is essential for success. Environmental factors, printhead characteristics, ink and substrate conditions, as well as process variables, all present challenges to colour accuracy. With constant monitoring, maintenance and advanced tools – such as ColorGATE’s Productionserver, Media Device Synchronization, Fingerprint Technology and Color Correction Loop Module – print-service providers can effectively overcome these challenges. This not only increases customer satisfaction, but also strengthens brand integrity and ensures long-term success in the competitive world of digital printing.