Color Matching - Ink Manufacturing

Color Matching - Ink Manufacturing

When a customer requests a specific color beyond standard black, cyan, yellow, or magenta, printers have two primary options: order the custom ink from a manufacturer or mix it on-site. Sourcing from an inkmaker is preferred for standard shelf inks or large quantity orders, while mixing in-plant is more practical for smaller amounts. Inkmaker color charts are essential references for this process.

In facilities with significant color matching demands, press operators typically do not mix inks. Assigning a dedicated specialist to this role proves more effective, offering superior economic efficiency and quality control.

The foundation of effective color matching is a strict formula method. For every mixed color used in production, each ingredient—including additives like driers—must be carefully weighed and its quantity recorded. See Figure 5-14.

Once the correct shade is achieved, a large batch is mixed according to the precise formula. A sample from the printed job is then preserved, with the formula and date recorded on its back. For lightfast colors, samples should be retained for no more than one year. It is also critical to note the job name and/or number on the sample for potential reprints. All inks used should be documented with their brand, name, number, and weight.

Ink samples can be prepared using a spatula, rolled out with a Quickpeek tester, or printed on a proof press and allowed to dry. Comparing one sample exposed to atmospheric conditions overnight with another sealed in a book provides valuable insight into the ink's drying behavior.

When an ink color is expected to shift during drying, two or three small samples may be mixed. For instance, if a green made from specific blue and yellow pigments is anticipated to dry bluer, a second sample with less blue is prepared. The sample drying closest to the target color is selected. If the desired result falls between two samples, a new formula can be derived by combining the ratios from the initial attempts.

Creating a tint involves adding an extender or a white transparent tinting medium to a colored ink. The most efficient method for printers to match a required shade is to gradually add the stronger color to the lighter one. All matches should be evaluated under multiple light sources to check for metamerism—the phenomenon where colors match under one light source but not another.

Without a firm grounding in color theory and accurate color perception, individuals often resort to inefficient trial-and-error matching. Professional color matching systems are available to eliminate this guesswork.

Looking ahead to 2026, the printing industry continues to integrate advanced digital workflows for greater color consistency and reduced waste. Sustainability remains a key driver, with increased focus on the environmental footprint of ink production and usage. Automation in color management is also enhancing precision and efficiency across both offset and digital print platforms.