Understood.

I will conduct a comprehensive investigation into the best practices, tools, and
solution providers—particularly those based in or available to India—for the accurate and
consistent formulation of special, non-Pantone colors in offset printing. I’ll explore industry
standards, equipment, software, and service providers, and compile practical
recommendations, case studies, and reports to support your objectives.

I’ll notify you once the detailed report is ready for your review.

Custom Color Formulation in Offset Printing: Best Practices, Tools, and Key Suppliers

Introduction

Offset printers often need to reproduce special branded colors that fall outside standardized
systems like Pantone. Unlike Pantone formula guides (which provide mixing recipes for pre-
defined colors), custom colors require a robust in-house process to formulate and consistently
replicate the exact hue across print runs. This involves careful ink mixing, precise color
measurement, and strict quality control. Many modern packaging and print applications rely on
unique spot colors for brand identity, as shown in the colorful packaging examples below
(Custom Ink Formulation Services - Castle Pierce). Achieving these custom spot colors reliably
demands a combination of traditional ink-mixing skills and advanced color management
technology. This report outlines industry-standard methods for formulating custom inks,
essential tools and software that ensure accuracy and repeatability, illustrative workflows from
the field, and suppliers (with an emphasis on those serving the Indian market) that provide
relevant solutions. Short, actionable recommendations are also provided to help offset printers
streamline their custom ink processes.

Challenges of Custom Color Mixing and Importance of Consistency

Formulating a non-Pantone color is challenging because there is no pre-set formula – the printer
must derive the recipe from scratch. Traditionally, many press operators mixed inks by eye and
experience, comparing the mixed ink to a physical sample or swatch. Visual matching alone,
however, is prone to error. As one industry discussion notes, relying on an operator’s judgment
can lead to significant color differences between the intended color and the final print, resulting
in high reject rates and rework (Explaining Spot Color Ink Mixing Techniques). Even a skilled
technician can struggle to judge color by eye under varying lighting or with different ink film
thicknesses. Human vision is subjective and can miss subtle deviations, whereas instruments
can detect minute differences. In fact, having standardized measurement procedures and
equipment is considered essential – without them, it’s difficult for an ink maker or printer to
ensure their custom-mixed inks will perform consistently on press ( Using a Spectrophotometer
to Improve Color Quality and Performance of Offset Inks | HunterLab ).

Moreover, colors that look acceptable under one light may mismatch under another (a
phenomenon known as metamerism). This risk is higher if the ink is mixed with an imprecise
combination of pigments. Even if a visually mixed color seems close, slight inconsistencies in
how the ink is prepared (ink layer thickness, mixing uniformity, etc.) can lead to noticeable shifts
when printed (Explaining Spot Color Ink Mixing Techniques). Overall, the stakes for accuracy
are high: brand colors must be reproduced exactly across different batches and print jobs to
maintain brand identity. This is why the industry has largely moved to instrument-aided color
matching, using devices and software to remove guesswork. By adopting a spectrophotometer-
based workflow, printers can detect even the smallest color variations that the human eye
might overlook, thereby reducing errors and ensuring a closer match to the target color ( Using a
Spectrophotometer to Improve Color Quality and Performance of Offset Inks | HunterLab ).

Another challenge is repeatability – once a custom color is achieved, the printer must be able
to mix it again next week or next year for a reprint. Achieving this requires detailed record-
keeping of the formula and process. The keys to a well-managed ink department include
maintaining accurate ink-mixing records and usage data so that the correct color can be
reproduced time after time with the right ingredients and amounts (Bring Order to Your Inkroom
with Ink-Management Software - Screen Printing Mag). A lack of process control can result in
one batch of “custom blue” not quite matching the next. Consistency is critical not just within a
single print run but across different runs and even across multiple printing presses or sites.

Best Practices for Formulating and Reproducing Custom Inks

To tackle these challenges, experienced offset printers and ink technicians follow a structured
approach. Below are best practices and standard methods for accurately mixing a custom
spot ink and reliably reproducing it:

• Define and Measure the Target Color: Start with a clear definition of the desired color.
This could be a physical sample from the client (e.g. a fabric, painted object, or previous
print) or a color specification in CIELAB values. Use a spectrophotometer to measure
the sample’s color values objectively. A spectrophotometer will capture the color’s
fingerprint (its exact L*a*b* coordinates and spectral reflectance), which serves as the
quantitative target for formulation (Explaining Spot Color Ink Mixing Techniques). This
instrument-driven measurement reduces reliance on visual perception and provides a
repeatable reference for the color. Industry experts strongly recommend moving away
from purely visual matching to spectrophotometer-based color formulation whenever
possible, to avoid subjective errors and metamerism issues (Explaining Spot Color Ink
Mixing Techniques).

• Use a Color Formulation Software: Armed with the target color data, employ
specialized ink formulation software to calculate the mixing recipe. The software uses
the target’s spectral data and a database of base ink colors to compute the optimal
combination of inks that will produce the desired color. Modern programs (such as X-
Rite’s InkFormulation or Datacolor Match Pigment) allow the user to input the measured
L*a*b* values of the target color and then automatically suggest a formula using
available bases. They consider the specific ink set’s characteristics (strength,
undertone, opacity, etc.) and can even adjust the formula to account for substrate color
or ink film thickness. For example, the system might determine that a certain green can
be achieved with 50% of base yellow, 45% of base blue, and 5% of extender by weight.
This computer-guided approach greatly reduces trial-and-error – it provides an
excellent starting formula that often just needs minor tweaking (Explaining Spot Color
Ink Mixing Techniques). If the initial mix isn’t perfectly on target, the software can iterate:
after you test-print or draw down the mixed ink and measure it again, the program will
adjust the recipe to correct any deviation (bringing the result within a tight Delta E
tolerance) (Explaining Spot Color Ink Mixing Techniques). This loop continues until the
color match is within acceptable limits. By contrast, purely manual mixing might require
many rounds of adding a bit of this or that ink, which is time-consuming and less
precise.
• Work with a Standardized Set of Base Inks: Consistency begins with the inputs. It’s
important to use a fixed palette of mixing base inks (such as the Pantone base colors or
a similar set provided by your ink supplier) and stick to those for formulating custom
colors. Using standardized bases means your formulas will be reproducible as long as
you have those same components. Each ink manufacturer offers its own line of mixing
inks with known properties, and formulas are usually specific to a given ink series.
Mixing different brands or series of inks can lead to unpredictability – the colorants
might have different strength or hue, and in worst cases incompatible chemistries could
cause issues (like pigment flocculation or ink “coagulation”) (Explaining Spot Color Ink
Mixing Techniques). Therefore, choose a single supplier’s ink series for your custom
mixes and obtain all the primary colors in that series. As a best practice, minimize the
number of distinct base inks used in a single recipe – using too many different
pigments can muddy the color and increase metamerism risk. The ideal formula uses
the fewest components necessary to match the color. Printers have found that limiting
the mix to 2–3 colors (plus extender or varnish as needed) yields better saturation and
consistency (Explaining Spot Color Ink Mixing Techniques). In sum: keep a consistent
stable of bases and use a simple recipe whenever possible.

• Use Precision Weighing and Clean Mixing Techniques: All ink ingredients should be
weighed accurately (typically in grams) according to the formula. Small errors in
proportions can lead to noticeable color shifts, especially for critical hues. It’s
recommended to use a digital scale with fine resolution (±0.1 g or better) for mixes,
particularly for small batches. For very small quantities (e.g. a few hundred grams of
ink), a scale that reads to two decimal places (0.01 g) helps ensure accuracy. Measure
each component carefully and record the exact weights used. The mixing itself should
be thorough – use a clean spatula or an ink mixing blade on a slow mixer to blend until
the color is uniform. In offset ink mixing, sometimes an automatic ink mixer (a device
that rotates or shakes a sealed can of ink) is used to achieve homogeneity, especially if
the ink is very viscous. Consistency in mixing technique is important: the same person
should use the same method each time to reduce variability (Explaining Spot Color Ink
Mixing Techniques). Also ensure all mixing tools and containers are clean and free of any
dried ink or contaminants before use (even a small amount of residual ink from a
previous mix can contaminate the color). Keeping the mixing area clean and following
the formula exactly leads to repeatable results.

• Account for Substrate and Ink Film Thickness: The appearance of a color can vary
depending on the paper or material it’s printed on and the ink layer thickness. It’s crucial
to test the custom ink under conditions that mimic the final production. Always proof
the color on the same substrate that will be used in the job (or one with very similar
color and finish) (Explaining Spot Color Ink Mixing Techniques). For example, an ink
might look slightly different on a bright white coated stock versus an uncoated kraft
stock. During formulation, some software can adjust for substrate color by including the
paper’s whiteness in the calculations. Practically, printers often create an ink
drawdown or proof by applying a sample of the mixed ink onto the actual paper. This
can be done with a small hand roller, a drawdown bar, or using a printability tester (like
an IGT proofing device). The drawdown should have a uniform ink film similar to what the
press would lay down. Once the drawdown is dry, inspect the color under standard
lighting (typically D50 lighting, which is a standardized daylight condition used in the
printing industry). Check both visually and instrumentally: measure the drawdown with
 the spectrophotometer to see how close it is to the target L*a*b* values. If the Delta E
(color difference) is beyond the allowed tolerance, adjust the formula as needed (the
formulation software can suggest how to tweak the recipe—adding a bit more of one
component or another—based on the measured error). This iterative approach
continues until the drawdown’s measured color is a near-perfect match to the target.

• Verify with a Spectrophotometer and Set Tolerances: A spectrophotometer is your

best friend for quality control in custom color matching. As noted, it can detect tiny
differences invisible to the naked eye. Establish an acceptable tolerance (e.g. Delta E
<= 2.0) for the color match, depending on customer requirements. When your test
sample falls within this tolerance compared to the reference, consider the color
approved. It’s good practice to take note of the final Delta E achieved. The
spectrophotometer’s ability to store color data is also valuable – many devices or
associated software allow you to save the target color and the achieved formula color
readings. This data can be recalled later to verify future batches. By quantifying color,
you remove ambiguity: instead of saying “looks a bit too warm,” you can say “Delta E =
1.2, mostly on the +a* side (slightly too red),” which is precise. Instrument-based QC
ensures that every batch of that custom ink is checked against the same standard. As
one ink industry expert highlights, spectral analysis and data storage for each batch help
guarantee consistency across batches and even enables quantifying the color for repeat
runs ( Using a Spectrophotometer to Improve Color Quality and Performance of Offset
Inks | HunterLab ) ( Using a Spectrophotometer to Improve Color Quality and
Performance of Offset Inks | HunterLab ). In other words, measure everything – you can’t
depend on eyes alone for critical color matches.

• Record the Formula and Process Details: Once a color is successfully matched,
document everything for future repeatability. This includes the exact formula (each
component and its weight or percentage), the base inks used (including
manufacturer/series and ink lot if possible), the substrate and finish, and any additives
(like extenders or varnishes) in the ink. Modern ink formulation software makes this easy
by allowing you to save the formulation in a database with a unique name or code. For
instance, if you create a custom orange for “ABC Corp Logo Orange”, you can save it
under that name and recall the recipe next time. In professional workflows, the ink’s
spectral profile and density values are also saved alongside the formula. Storing these
specs in a centralized system or software is critical – it ensures that when you need
to remake the color, you have an authoritative recipe and target to work from (Custom
Ink Formulation Services - Castle Pierce). Some printers also keep a physical swatch (a
dried drawdown of the approved ink) labeled with the formula as a visual reference.
When the next order for that custom color comes, you can mix according to the saved
formula, produce a drawdown, and compare the new drawdown both visually and with a
spectro to the original standard (physical and/or digital) to confirm it matches. This
closes the loop on consistency – the process becomes rinse-and-repeat rather than
starting over each time. Robust record-keeping is a cornerstone of consistent custom
color production.

• Maintain Consistency During the Press Run: After all the careful ink formulation work,
it’s important to also control variables on the printing press so the color prints
consistently. Calibration and standardization on press will ensure the custom ink
looks the same throughout the run and in future reruns. Use press-side color
 measurement tools (like a handheld spectrophotometer or densitometer) to monitor the
ink density and color on the sheet. For example, you might measure color patches of the
custom ink in the color bar of each press sheet to ensure it stays within the Delta E
tolerance from the proof. If the press has inline or at-line spectral scanning systems,
leverage them to catch any drift. Repeatability means that not only is each batch of ink
the same, but how you lay it down on paper is the same too. Keep variables like ink film
thickness, fountain solution, drying conditions, and paper lot as consistent as possible
with the conditions under which the color was approved. If any adjustments are needed
(e.g. slight ink feed increase or reduction), do so carefully and re-check color. By
integrating the custom ink into your overall color management process (similar to how
you’d treat a Pantone color on press), you ensure the final output meets expectations.
Many offset printers follow ISO or G7 process control methods for CMYK; similarly, spot
colors can be managed by setting target Lab values and densities and monitoring them
throughout the run. In essence, treat custom spot colors with the same rigor as you
would your standard process colors.

By following the above practices – from initial measurement and formula calculation to careful
mixing, testing, and documentation – printers can achieve accurate and repeatable custom
colors. Notably, these steps mirror what ink manufacturers do in their labs. Ink companies rely
on spectrophotometers and formulation software to create new colors with consistent quality.
Adopting these industry-standard methods in the print shop brings a level of professionalism
and precision that significantly reduces trial-and-error, waste, and reprint costs.

Essential Tools and Technologies for Color Precision

Producing special colors consistently is not just about technique; it also requires the right tools.
The printing industry has developed a suite of instruments, software, and equipment to enable
precision in color formulation. Below we discuss the key tools and equipment that
professionals use to ensure color accuracy and repeatability, along with best practices for each:

Spectrophotometers and Color Measurement

A spectrophotometer is a cornerstone of modern color matching. This instrument measures

the reflectance of colored samples across the visible spectrum, allowing it to capture exact
color values and detect even subtle differences. In an offset printing context, a
spectrophotometer is used at multiple stages: measuring the target color, formulating the ink (in
conjunction with software), and verifying the final result. Spectrophotometers commonly used
in print shops include handheld devices like the X-Rite eXact or Konica Minolta FD-series, as
well as bench-top models for laboratory settings. These devices report color in precise terms
(such as CIELAB coordinates and spectral curves) and can calculate ΔE (Delta E) values to
quantify the difference between two colors.

The benefit of using spectrophotometers is well-documented. They remove the guesswork from
color matching and provide a quantitative quality control. For instance, spectral analysis can
pick up slight variances in hue or saturation that a person might not notice, thereby
guaranteeing closer matches and batch-to-batch consistency ( Using a Spectrophotometer
to Improve Color Quality and Performance of Offset Inks | HunterLab ). Equally important,
spectros can save measurements into memory or a database – building a library of custom
colors that can be referenced later ( Using a Spectrophotometer to Improve Color Quality and
Performance of Offset Inks | HunterLab ). This makes future reproductions much more reliable,
since you’re aiming for the same numerical target each time rather than relying on memory or
subjective comparison. Many spectrophotometers connect to software or printers’ quality
control systems, allowing integration into an overall color management workflow.

For best results, it’s crucial to use the spectrophotometer properly: calibrate it as
recommended (usually on a white tile provided with the instrument), take measurements on
flat, uniformly inked samples or color patches, and use consistent backing (e.g. backing white
or black, per standard, when measuring paper samples). Also, measurements should be taken
under standardized illuminants/observers (D50/2° is common for print) so that the data is
comparable to industry specs. In summary, a spectrophotometer is an indispensable tool for
any printer aiming to mix and reproduce custom colors accurately – it provides the data-driven
approach needed for high precision.

(Note: Densitometers, which many offset printers use for process control, measure ink density
but not color hue. A densitometer can tell you how heavy the ink film is, but not whether a
custom green is shifting toward blue or yellow. Spectrophotometers, on the other hand, can
detect color shifts. Many modern devices like the X-Rite eXact actually function as both
densitometer and spectrophotometer.)

Ink Formulation and Color Matching Software

Ink formulation software is the brain of the custom color workflow. These programs use color
science algorithms to derive ink blend recipes that match a target color. Leading solutions in the
market include X-Rite InkFormulation, Datacolor Match Pigment, and others like ChromaInk,
Esko Color Engine, or ink supplier proprietary systems. The general capabilities of formulation
software are: storing libraries of base ink data (including their color values and strength),
suggesting formulas for new colors, adjusting formulas based on measurement feedback, and
maintaining a database of saved color formulas.

By using such software, printers can dramatically cut down the time spent on trial-and-error
mixing. Instead of manually adding a bit of one ink and testing, the software calculates the
optimal mix in one go. As one print technology article notes, allowing the “brains” of an ink
management program to calculate ink formulas eliminates much of the guesswork and human
error (Bring Order to Your Inkroom with Ink-Management Software - Screen Printing Mag). The
user simply selects or inputs the target color (which could even be a Pantone color or any
custom Lab value), and the program outputs the mix proportions needed. Many software
packages come pre-loaded with the Pantone formula library and also allow the user to add their
own custom color formulas to the database (Bring Order to Your Inkroom with Ink-Management
Software - Screen Printing Mag).

Crucially, these programs maintain accurate records of each formula and can scale the
formula to any batch size. You can enter how much ink you need (for example, 5 kg) and the
software will calculate exactly how much of each component to weigh out (Bring Order to Your
Inkroom with Ink-Management Software - Screen Printing Mag). This not only ensures you mix
enough ink for the job but also helps avoid wasting ink by over-mixing. Advanced features of ink
formulation software often include: integration with electronic scales (where the software
guides the operator to dispense each ingredient and can correct if an overdose occurs) (Bring
Order to Your Inkroom with Ink-Management Software - Screen Printing Mag), inventory tracking
(deducting the amounts used from inventory records), and even cost calculations. Some
programs can suggest formulations using leftover inks to reduce waste (e.g. using an existing
surplus ink as part of a new formula) (Bring Order to Your Inkroom with Ink-Management
Software - Screen Printing Mag) – this is especially useful if you frequently mix custom colors
and want to reuse inks from previous jobs when their colorant makeup aligns with a new color’s
requirements.

For offset printers, a formulation software coupled with a spectrophotometer is often sold as a
package. For example, X-Rite’s InkFormulation software can work with their
spectrophotometers to create and store formulas for offset inks (Offset Printing Ink Formulation
| X-Rite Blog). These tools are designed to handle the specific pigments and transparency of
printing inks. Overall, implementing an ink formulation system brings a high level of control
and repeatability to custom ink mixing: once a formula is determined and saved, the software
ensures you can recall it and mix it the same way every time. This consistency is virtually
impossible to achieve with purely manual methods. In short, ink formulation software provides
the consistency, efficiency, and data management that are now considered industry best
practice for custom color work (Bring Order to Your Inkroom with Ink-Management Software -
Screen Printing Mag).

Ink Dispensing and Mixing Equipment

Mixing inks by hand on a slab or with a spatula can be labor-intensive and inconsistent,
especially when dealing with larger volumes or many custom colors. To address this, many
printing companies (particularly in packaging and label segments) use ink dispensing systems.
An ink dispensing system (also called an ink dispenser or “ink kitchen” system) is a machine
that automatically dispenses specified amounts of each base ink into a container to mix a
formula. These systems are gravimetric – meaning they dispense by weight. The core
components are a computer control unit, a scale, and a series of pumps/valves connected to
base ink containers (which could be 1kg cans, 20kg pails, or even 200kg drums, depending on
the scale of operation) (Ink dispensing: the basics - GSE Dispensing) (Ink dispensing: the basics
- GSE Dispensing). Once the desired formula and batch size are selected on the computer, the
dispenser sequentially doses each ingredient to the target weight with high precision (often to
within 1 gram) (Ink dispensing: the basics - GSE Dispensing). If it overshoots an ingredient
slightly, the system’s software will automatically compensate by reducing another ingredient to
maintain color accuracy, a feedback loop that ensures the final mix still meets the formula spec
(Ink dispensing: the basics - GSE Dispensing). The result is a bucket of ink mixed quickly (usually
in just a few minutes) and extremely accurately, ready to go to press (Ink dispensing: the basics -
GSE Dispensing).

The advantages of automated ink dispensing are significant for those who mix colors frequently
or in large volumes. They offer speed (much faster than manual weighing of multiple inks) and
consistency (each batch is dispensed exactly the same). Waste is minimized because you
dispense just what you need, and any slight over/under in one component is adjusted
automatically. According to an industry report, benefits of automatic ink dispensers include
virtually unlimited color range, instant formula recall, accuracy up to 1 gram, the ability to mix
even small quantities, reduction of ink inventory, better management of leftovers, and
elimination of mixing errors ( With 10 installations, Inkmaker seeking to expand | INKMAKER SRL
). In practical terms, this means improved efficiency and cost savings: less leftover ink to store
or discard, fewer rejected batches, and less downtime waiting for inks to be mixed. For example,
packaging printers who might mix dozens of spot colors a day rely on dispensers to keep up with
production and maintain consistency.
For a smaller offset printer, a full-scale dispenser might not yet be justifiable, but intermediate
solutions exist. Some shops use semi-automatic dispensing: a scale connected to
formulation software that guides the operator step-by-step through weighing each ink (often
displaying progress on-screen and adjusting targets if an overpour happens) (Ink dispensing: the
basics - GSE Dispensing). This is slower than a fully automatic dispenser but still ensures
accuracy and can be a more affordable way to improve the mixing process. Even at a basic
level, using a gyroscopic ink mixer (a machine that clamps a can of ink and spins/shakes it
thoroughly) can help achieve a uniform mix, especially if you add dry pigments or other
modifiers to an ink – this ensures no streaks or undispersed bits remain.

In summary, ink dispensing equipment brings industrial precision to ink mixing. It’s especially
beneficial if you handle a high volume of custom colors or require ultra-consistent results. Many
large printers and in-plant ink departments have these systems in place as part of their color
workflow. For smaller operations, starting with a good scale and software (the “manual but
guided” approach) can yield a big improvement in repeatability over purely manual mixing (Ink
dispensing: the basics - GSE Dispensing). As demand for brand-specific colors grows, investing
in an ink dispensing “kitchen” can become a competitive advantage for an offset printer by
enabling faster turnarounds and exact color matches every time.

Additional Color Control Tools

Beyond the main players (spectros, software, dispensers), there are other tools that contribute
to a reliable custom color process:

• Standard Lighting and Viewing Booths: Since perceived color is heavily influenced by
lighting, it’s important to evaluate color under standardized light conditions. A D50 light
booth (5000 K daylight simulator) is commonly used in the printing industry. After mixing
a custom ink and printing a sample, viewing it in a light booth ensures both the printer
and the client see the color in the same light, reducing disagreements caused by
metamerism. As noted earlier, metamerism can make two inks look identical in one light
and different in another (Explaining Spot Color Ink Mixing Techniques); a good practice is
to check the print under multiple lights (D50, TL84 fluorescent, and tungsten are typical
in a multi-source light booth) to ensure the color match is solid. Consistent viewing
conditions eliminate variability – a color approved in the booth will likely match on press
under the same lighting standard used in pressrooms or client inspection areas.

• Color Guides and Physical References: While the Pantone Matching System may not
directly solve custom colors outside its library, Pantone books can still serve as a
communication tool. Often a custom color request will start by saying “it’s between
Pantone X and Pantone Y” or “darker than Pantone Z.” Having Pantone fan decks on hand
can help communicate with clients about the desired direction of a color. Additionally,
custom swatch books or sample catalogs can be developed in-house over time –
essentially a binder where you keep labeled swatches of custom colors you’ve mixed
before. This becomes an internal reference so you can show clients or check against a
previous job’s color quickly. Some printers also use systems like the Munsell color
book or the NCS (Natural Color System) to discuss colors, though these are more
common in paint and design than printing. The key is to have physical references to
guide the formulation and approval process.
 • Quality Control Strips and Densitometers: On press, using color control strips (with
patches of the custom spot color if possible) and measuring them with a densitometer
or spectrophotometer helps maintain uniform color. A densitometer can’t tell color hue,
but it can ensure you’re laying down the same ink film density as during the proof. If you
notice density drifting, you can adjust the ink keys to bring it back in line, which in turn
keeps the color close. Many modern presses or console systems can scan a color bar
and even do closed-loop adjustments. For spot colors, closed-loop control is less
common than for CMYK, but at least having the operator measure and log the
density/Lab* of the spot at intervals is a good practice. Press calibration (e.g. if you
have a certain standard density that the custom ink should be run at) also falls under
best practices so that the color prints the same each time. In sum, once the ink is right,
ensure the printing conditions are right.

• Environmental Controls: Ink mixing should ideally be done in a controlled environment

– moderate temperature and humidity – because extreme conditions can affect ink
viscosity and drying. If your mixing room is very cold or very hot, it might subtly change
how the ink handles (for example, a very cold stiff ink might not form a smooth
drawdown and could lead you to over-adjust the formula). Some large ink labs actually
warm thick inks slightly to improve flow when mixing; one source suggests pre-warming
highly viscous inks to about 100°C and cooling them before making proof samples, to
improve flow and color uniformity (Explaining Spot Color Ink Mixing Techniques). While
such steps might be beyond the scope of a typical print shop, the principle is to keep
conditions consistent. Also, avoid direct bright light when mixing (to prevent any light-
sensitive pigment issues or drying) and minimize time the ink is exposed to air (to
prevent skinning or solvent evaporation in case of solvent-based inks).

• Training and Color Knowledge: Lastly, the tools are only as good as their operator.
Ensuring that staff are trained in using spectrophotometers (e.g. knowing how to take
consistent measurements), understanding Delta E, operating formulation software, and
handling inks properly will greatly improve outcomes. For instance, understanding
pigment properties (like a certain blue pigment is very strong, or a certain red is prone to
metamerism) can inform decisions during formulation. Many ink suppliers or equipment
vendors offer training sessions or support to help printers implement these systems
effectively.

The combination of these tools and practices forms an ecosystem of color management for
custom inks. A printer who invests in good measurement devices, software, and possibly
dispensing hardware, and who follows proper procedures, will find that matching a client’s
special color becomes a straightforward, repeatable task rather than a stressful art of
eyeballing. This leads to faster turnarounds, less material waste, and greater customer
satisfaction due to right-first-time color accuracy.

Industry Examples and Workflows

To illustrate how these best practices and tools come together, it’s helpful to look at how
industry professionals handle custom color formulation in real scenarios:

• In-Plant Ink Formulation Service (Case: Castle Pierce packaging) – Castle Pierce, a
packaging printer in the U.S., provides a useful example of a streamlined custom ink
workflow. They partnered with an ink supplier (INX International) that operates an in-
 plant ink formulation service for them (Custom Ink Formulation Services - Castle
Pierce). In this setup, the ink supplier’s technicians manage color mixing on-site. Castle
Pierce reports that photospectrometers and scanning equipment ensure ink color
remains consistent and accurate throughout a press run, with ink draw-downs and
proofs used to check color matching before and during printing (Custom Ink
Formulation Services - Castle Pierce). Once a color is matched, the ink’s specifications
(formula, density, etc.) are recorded in proprietary ink formulation software so that
future reprints of that color can be supplied and mixed with identical results (Custom
Ink Formulation Services - Castle Pierce). This approach shows a fully integrated
workflow: initial formulation with spectrophotometric confirmation, ongoing quality
control on press, and digital record-keeping for repeatability. The result is that brand
colors are consistent across different orders and even across different print processes
(the data can be shared, ensuring brand integrity in color is maintained) (Custom Ink
Formulation Services - Castle Pierce). Essentially, Castle Pierce outsourced the
complexity to ink experts but still uses the same core tools and principles we outlined,
demonstrating their effectiveness. The takeaway is that whether handled internally or
via a supplier, a combination of spectrophotometric measurement, software-driven
formula tracking, and rigorous QC yields reliable custom colors.

• Traditional vs. Modern Mixing (Comparison) – Another example can be drawn from
experiences shared by printers moving from older methods to newer ones. A common
scenario: a customer needs a rush job with a custom color. In the past, a printer might
have manually mixed inks trying to visually match a sample, which could take multiple
tries and valuable time, with no guarantee of precision. One trade article vividly
described the “panic” of searching for a recorded formula or rushing to mix a custom
color by eye for a rush job (Bring Order to Your Inkroom with Ink-Management Software -
Screen Printing Mag). The modern approach, by contrast, is to quickly measure the
customer’s sample with a spectrophotometer, pull up a suggested formula in seconds
from the software, and mix it with confidence that it will hit the mark. This dramatic
improvement is echoed in testimonials: Printers avoid the delay and cost of ordering
premixed ink (which often has minimum order quantities and lead time) by mixing in-
house, provided they have an organized system (Bring Order to Your Inkroom with Ink-
Management Software - Screen Printing Mag). Shops that implemented ink formulation
software have noted that it became invaluable for hitting the right color “time and time
again” while also maintaining proper inventory of bases (Bring Order to Your Inkroom
with Ink-Management Software - Screen Printing Mag). We see across the industry that
those who invest in these color tools rarely go back – the predictability and efficiency are
too beneficial.

• Use of Ink Dispensing in Packaging – In high-volume sectors like flexible packaging and
labels (which often use offset for cartons or combination of litho and flexo), the use of
ink dispensing systems is prevalent. For example, many large packaging converters in
India and worldwide have installed automated dispensers to handle their spot colors.
GSE Dispensing, a Dutch manufacturer of ink dispensers, has reported numerous
installations of its Colorsat dispensing systems at packaging printers and ink suppliers
in India ( With 10 installations, Inkmaker seeking to expand | INKMAKER SRL ) ( With 10
installations, Inkmaker seeking to expand | INKMAKER SRL ). These systems blend base
inks automatically to produce precise spot colors on-demand. The fact that ink
manufacturers themselves use such dispensers and then recommend them to printers
 speaks to their effectiveness ( With 10 installations, Inkmaker seeking to expand |
INKMAKER SRL ). An automated dispenser becomes the hub of a printing company’s ink
room, ensuring every operator pulls inks in the same way with the same results. As an
example, Inkmaker (another dispensing system provider) highlighted that their users see
absolute accuracy up to 1 gram, instant color formula recall, and major stock reduction
in inks when using these systems ( With 10 installations, Inkmaker seeking to expand |
INKMAKER SRL ). Printers have been able to reduce their inventory of pre-mixed spot
inks, since they can mix just-in-time, and also efficiently reuse surplus inks. A case in
point: one printer might take leftover inks from previous jobs and feed them into new
recipes (something the software can calculate, as noted earlier about recycling
functions), thus reducing waste significantly. The broad industry trend is that advanced
“ink kitchens” are becoming standard in large print operations for managing special
colors, and even smaller print shops are adopting scaled-down versions of these
technologies to remain competitive on color capability.

• Supplier Collaboration – Many printing companies achieve success with custom colors
by working closely with their ink suppliers. For instance, hubergroup (Micro Inks) in India
and other global ink suppliers often provide what’s called an implant. This is similar to
the Castle Pierce example: the ink company sets up a small lab at the printer’s site or
provides a dedicated color technician to formulate and manage inks. These
partnerships leverage the supplier’s expertise and tools. In India, it’s not uncommon for
a packaging printer to rely on, say, Sakata INX or DIC India to deliver custom spot inks
mixed exactly to spec. However, even in these cases, having in-house verification tools
(like a spectrophotometer) is wise so the printer can double-check incoming custom
inks and ensure they meet the required Lab values or Pantone references. A
collaborative approach might involve the supplier providing initial formula support and
the printer then maintaining the color with their own QC during the run.

Each of these examples underscores a common theme: the use of systematic, technology-
driven workflows for custom color formulation leads to better outcomes. Whether the
capability is fully in-house or supported by an external ink partner, the combination of good
measurement, software, and process control is key. Printers who implement these methods
can confidently offer custom color matching as a service, knowing they can hit the target color
and reproduce it later with minimal fuss. This capability can be a differentiator in the market –
for instance, a printer can say to a client, “Give us any color sample, and our color laboratory
will formulate an exact match for your print job, which we’ll maintain consistently.” Not only
does this inspire customer confidence, it also streamlines production internally (less time
tweaking on press, less ink wasted, fewer customer complaints about color).

Key Suppliers and Solutions (with Focus on India)

To implement the best practices above, printers will likely need to procure the right tools and
possibly consult with solution providers. Below is a rundown of major companies and
suppliers that offer relevant technology or services for custom ink formulation and color
management. The emphasis is on those available in the Indian market (in many cases via local
distributors or subsidiaries):

• X-Rite Pantone: X-Rite (a U.S.-based company, which owns Pantone) is a leading

provider of color measurement instruments and software. They manufacture
spectrophotometers commonly used in printing (e.g., the X-Rite eXact series for
 pressroom color measurement, Ci64 handheld, etc.) and offer the InkFormulation 6
software used for formulating custom inks. X-Rite’s solutions are considered industry-
standard – their spectros and Pantone libraries are used worldwide for ensuring color
accuracy. In India, X-Rite products are available through authorized distributors such as
Advanced Graphic Systems (AGS) and others. Printers can obtain X-Rite
spectrophotometers along with software and even Pantone reference books. X-Rite also
provides training and support; their presence (often through Pantone’s brand
recognition) in India is well-established. For instance, many Indian printers use X-Rite
eXact devices to measure spot colors and Pantone shades on press. Pantone itself
offers tools like the Pantone Formula Guide (physical swatch books) and Pantone Live (a
cloud-based digital color library for brand colors), which can be useful when
communicating and benchmarking custom colors, even if the final formulation is done
via other means.

• Konica Minolta Sensing: Konica Minolta (Japan) is another top maker of

spectrophotometers and color analyzers. Their instruments (like the Konica Minolta FD-
7 or CM-3600A bench unit) are used in printing and packaging for color formulation and
QC. Konica Minolta has an Indian subsidiary for their sensing division, making it easy to
access their products locally. They may not have dedicated ink formulation software like
X-Rite’s, but their devices can be used in conjunction with third-party software. They
also offer quality control software that can create color libraries and help with pass/fail
decisions for color matching. Printers looking for alternative or additional
spectrophotometers might consider Konica Minolta models, which are known for
reliability and cross-industry use (they are used in automotive, paint, textile, etc., as
well).

• Datacolor: Datacolor (USA/Switzerland) produces color management hardware and

software, traditionally strong in textiles and plastics but also applicable to inks. Their
Match Pigment software is a formulation system designed for paint and pigment
formulations, which can be used for printing inks as well. They also have
spectrophotometers (e.g., Datacolor Check, SpectraVision, etc.). In India, Datacolor has
representation focusing on textile mills, but the technology can certainly be extended to
print applications. If a printer or an ink manufacturer is looking for an integrated system
to formulate colors (especially across different materials), Datacolor’s solutions are
worth noting. They emphasize closed-loop color management – measuring, formulating,
and adjusting. An interesting angle is that Datacolor sometimes partners with ink
suppliers to provide tailored databases of inks in the software, similar to X-Rite’s
approach. Their presence in India includes support offices that can assist in setting up
formulations for local ink sets.

• Techkon: Techkon GmbH (Germany) is known for high-quality densitometers and

spectrophotometers for the graphic arts. Products like Techkon SpectroDens or
SpectroJet are used by some printers as alternatives to X-Rite devices. Techkon’s focus
is often on press-side color control (densitometry, color scanning), but their spectro
devices can measure Lab values for custom colors as well. Techkon is represented in
India through dealers (e.g., TechNova or others have carried their devices). While they
don’t provide an ink formulation package to our knowledge, they are a key supplier for
the measurement instrument itself. Printers who want to ensure competition in quotes
 or prefer German-made instruments might consider Techkon for their color
measurement needs.

• GSE Dispensing: GSE is a Netherlands-based company specializing in automated ink

dispensing systems and related software. Their Colorsat dispensers are widely used in
packaging (especially flexo and gravure, but also in offset carton printing for spot inks).
GSE’s ink management software can store formulations and drive these dispensing
units. In India, GSE has an exclusive agent – Weldon Celloplast – which provides their
equipment and support to Indian printers (Weldon to represent GSE's Colorsat ink
dispensing programme). For a printer aiming to set up an in-house ink dispensing
system, GSE (via Weldon) is a key contact. They offer systems ranging from small (for
label printers mixing small 1-5 kg batches) to large (mixing 200+ kg). GSE often
showcases at Indian print exhibitions like Labelexpo India, indicating a commitment to
the market. The benefit for Indian printers is local support for installation and
maintenance through the agent. GSE’s solutions help automate the custom color mixing
process, bringing the aforementioned accuracy and efficiency. They also advertise
waste reduction and easy recipe management as selling points – important for printers
looking to improve sustainability and cost control in the ink room.

• Inkmaker (IM GROUP): Inkmaker is an Italian-origin manufacturer of ink and paint

dispensing systems, now part of the IM GROUP. Notably, Inkmaker has a manufacturing
presence in Navi Mumbai, India, and has installed multiple systems in the country ( With
10 installations, Inkmaker seeking to expand | INKMAKER SRL ). They cater to ink
manufacturers as well as printing companies. Inkmaker’s systems similarly offer
gravimetric dispensing of custom colors with high precision. For instance, they have
models suitable for offset ink kitchens. Since they have a local manufacturing unit and
support team, Indian printers might find Inkmaker’s offerings accessible and well-
supported. Inkmaker systems come with their own management software to handle
formulations and inventory. They have highlighted successes in the Indian market,
especially for high-volume ink users (printers consuming >10 tons of ink per month) (
With 10 installations, Inkmaker seeking to expand | INKMAKER SRL ). If a printer is that
large, an Inkmaker or GSE system almost becomes a necessity to handle the volume of
custom mixing. Smaller printers could potentially look at Inkmaker’s lower-volume
dispensers or even manual dispensing stations that they offer. The key is that Indian
printers have multiple options for acquiring ink dispensing technology
domestically.

• Ink Manufacturers and Suppliers: The companies that make the inks are also crucial
partners in custom color formulation. Major ink suppliers in India (and globally) include
hubergroup (Micro Inks), DIC / Sun Chemical (through DIC India), Flint Group,
Siegwerk, Toyo Ink, Sakata INX (INX has a joint venture in India known as Sakata INX),
Huber Asia, and others. These companies often provide value-added services for color
matching. For example, hubergroup offers a system called NewV CRS for UV inks which
allows mixing any spot color with optimized properties (NewV CRS - The UV ink mixing
system for spot colours - Hubergroup). They also have software like Hu-Track for press-
side color corrections (Real-Time Colour Correction | USA - Hubergroup). Many of these
ink suppliers will gladly create a custom ink formula if you send them a color sample –
they have the high-end lab equipment to do it and can either supply the mixed ink or give
you the formula for use with their inks. In the Indian context, if a printer doesn’t have in-
 house capabilities, they might send a swatch to, say, Micro Inks (hubergroup’s plant in
Vapi, Gujarat) and get a batch of that custom ink delivered. The downside is cost and
time (small custom batches can be expensive and have lead times). Therefore, a middle
path is where ink suppliers provide mixing kits and formula guidance: e.g., they’ll
supply a set of base inks and a formula for the custom color which the printer mixes on-
site. This is quite common – a printer might call their ink rep and ask “How do I make this
color?” and the supplier gives a recipe using the inks they provided.

It’s worth noting that many of the ink companies have their own ink formulation software in their
labs. Some have started providing printers with access to databases of formulas (especially for
Pantone colors or common industry colors) that are specific to their ink lines. Siegwerk and
Flint have done this for packaging, for example – letting printers use an app or software to get
formulations for their inks. The Indian Printing Ink Manufacturers Association (IPIMA) and
other bodies sometimes facilitate knowledge transfer in this area as well. Ultimately, ink
vendors are stakeholders in your color success, so printers should leverage those relationships:
whether it’s obtaining high-quality base inks, getting technical support for difficult colors (like a
particular corporate logo orange that’s hard to match, or a metallic custom color), or even
setting up an on-site ink mixing station under the ink company’s guidance.

• Other Solution Providers: There are a few other notable mentions. Esko (part of
Danaher, like X-Rite) provides packaging workflow software and has a Color Engine
module for managing spot color profiles and proofing – it’s used more in prepress to
ensure the digital side matches the ink capabilities. GMG Color and EFI/Fiery also have
solutions for managing color (mostly in proofing/inkjet simulation of spot colors, which
can help in client approvals of custom colors before going to press). These may be
peripheral to our main focus but are part of the larger ecosystem ensuring the custom
color seen on a proof actually translates to the press ink formula. ChromaChecker and
other newer color QA platforms allow printers to track the quality of spot color
reproduction over time and across devices, providing cloud databases for custom
colors – these are useful in multi-site or multi-press scenarios.

Finally, for completeness, lighting equipment providers like GTI or Just Normlicht supply the
viewing booths mentioned earlier; and companies like BYK-Gardner supply additional lab tools
(drawdown cards, automated drawdown machines, etc.) that some larger ink labs or print QA
labs might use. In India, such equipment can be sourced via local dealers who specialize in
print and packaging testing tools.

Below is a summary table highlighting key categories of solutions and examples of suppliers for
each, with notes on their availability in India:

Solution Type Examples / Suppliers Notes (India Availability)

Essential for measuring and verifying

X-Rite (eXact handheld, colors. Widely available via Indian
Ci64, eXact 2), Konica distributors (e.g., X-Rite through AGS,
Spectrophotometers
Minolta (FD-5/7, CM Konica Minolta Sensing India). These
(Color Measurement)
series), Techkon devices ensure objective color matching
(SpectroDens), Barbieri and are standard in most professional print
shops.
Solution Type Examples / Suppliers Notes (India Availability)

Used to calculate and store custom ink

X-Rite InkFormulation,
recipes. Often bundled with or compatible
Datacolor Match Pigment,
with spectrophotometers. X-Rite and
Ink Formulation Esko Color Engine,
Datacolor products are accessible in India;
Software proprietary ink company
ink manufacturers may provide formula
software (e.g., hubergroup
support through their systems. Enables
CRS, Flint Color Suite)
faster matching and repeatability.

GSE Dispensing (Colorsat

Automates ink mixing by weight for high
systems), Inkmaker (IM
precision and efficiency. GSE (Dutch) and
GROUP systems), Rexson
Ink Dispensing Inkmaker (Italian) have active installations
(dispensers, now part of
Systems in India (via Weldon Celloplast for GSE, and
GSE perhaps), FUJIFILM
Inkmaker’s own India unit) ([ With 10
Ink Dispensing (for inks, in
installations, Inkmaker seeking to expand
some regions)

High-resolution digital scales (0.1g/0.01g)

are critical for accurate ink weighing –
Mettler-Toledo, Sartorius these can be sourced from lab equipment
(weighing scales); manual suppliers in India. Gyroscopic mixers or
Precision Scales &
mixing tools; shaker machines (often used in paint
Mixing Tools
Shakers/Gyro mixers (Red shops) are useful for ensuring thoroughly
Devil, Inkmaker) mixed ink, and are available via industrial
suppliers. These tools help maintain
formula accuracy and uniformity.

Provide controlled lighting (D50, D65, TL84,

GTI Color Viewing Booths, etc.) for visual color evaluation and to
Standard Lighting / Just Normlicht light detect metamerism. GTI and others have
Viewing Booths cabinets, D50 lighting distributors in India (sometimes through
setups graphic arts suppliers). Essential for
consistent visual approvals of color.

Used to monitor color during printing.

X-Rite (IntelliTrax2 Many new offset presses in India come
scanning system, eXact), with integrated color scanning systems for
Press-Side Color Techkon (SpectroDrive quality control. These ensure the custom
Control Instruments scanning), Heidelberg ink stays on target throughout the run.
Inpress Control (built into Handheld spectros (like X-Rite eXact) are
presses) also commonly used on older presses for
spot checks.

These companies supply the base inks and

Ink & Pigment hubergroup India (Micro often provide custom mixing support. All
Suppliers Inks), DIC India (Sun have operations in India and can deliver
Chemical), Siegwerk mixing systems or technical assistance.
For example, hubergroup’s local team
Solution Type Examples / Suppliers Notes (India Availability)

India, Sakata INX, Toyo might help a customer set up a mixing

Ink, Flint Group station with their inks. Strong supplier
relationships can bolster a printer’s
custom color capabilities (Ink dispensing:
the basics - GSE Dispensing).

Table: Key tools and supplier examples for custom ink formulation and color management
(including India-focused availability).

Recommendations for Streamlining Custom Color Processes

Given the discussion above, here are actionable recommendations for offset printers looking
to improve their custom color formulation workflow, with an eye toward repeatability and
efficiency:

1. Adopt Instrumentation and Software: Invest in a good spectrophotometer and

compatible ink formulation software. This duo will form the foundation of a reliable color
mixing process. By measuring colors and using software to compute formulas, you
eliminate much of the guesswork and ensure accuracy. As industry experts note, having
standard instruments and procedures is essential for consistent results ( Using a
Spectrophotometer to Improve Color Quality and Performance of Offset Inks |
HunterLab ). Start by formulating all new custom colors with the aid of these tools –
you’ll quickly see more first-pass matches and fewer re-mixes. Over time, build a digital
library of your custom colors in the software so that you can easily retrieve formulas for
repeat jobs.

2. Standardize Base Inks and Mixing Materials: Choose a stable set of base inks
(preferably from one manufacturer/series) for all your mixing needs and stick with them
(Ink dispensing: the basics - GSE Dispensing). This ensures that your formulas remain
valid and consistent. Keep those base inks well-stocked and properly sealed to prevent
any changes (like solvent evaporation or aging which could affect color strength). Also,
use standardized additives – for example, if you need to adjust tack or drying, use the
same additives in consistent amounts. Having a fixed “ink palette” and process means
that when the software says 5% of base red, it’s always the same red you’re adding. This
dramatically improves repeatability. It also simplifies inventory and works in harmony
with formulation software databases (which are typically set up for specific ink lines). If
you ever need to change a base ink (due to supplier change or new series), re-
characterize it in your software and avoid mixing old and new bases in one formula.
Consistency of inputs = consistency of outputs.

3. Implement Rigorous Record-Keeping: Make it standard practice to document each

custom color’s details – formula proportions, actual weights used, color values,
substrate, date, etc. Ideally, use your formulation software to save these, but also
consider printing out a “recipe card” or keeping a log book as a backup. The record
should be detailed enough that someone else could replicate the color from it. This
archive is gold when a repeat order comes in. It also helps in troubleshooting (if a color
didn’t match well, notes could indicate what might have gone wrong). Leverage software
features to maintain these records – for example, many programs can print a label or
 report for each batch mixed, which you can file. By having an organized formula library,
you transform custom color matching from an art into a science that anyone on your
team can reproduce.

4. Use Controlled Proofing and Approval Procedures: Before committing a custom color
to a big print run, always produce a controlled sample (drawdown or proof) and get it
approved – either internally against the standard or by the client if they require it. This
proof should be made on the actual job stock at the correct ink film thickness. Measure
it with the spectro and also inspect visually under a light booth. Doing this due diligence
will catch any issues early. It’s much easier to tweak an ink formula in the lab than on
the press. Once approved, treat that proof as the master standard – store it safely.
Then, in press runs, aim to match that standard (with spectro checks or at least visual
side-by-side comparison in the light booth). Essentially, institute a policy: no custom
color goes to press without a spectro-verified drawdown approval. This will save time
and money by avoiding press stoppages to adjust color.

5. Integrate Color Quality Control in Press Operations: Train press operators to use the
spectrophotometer or a densitometer to monitor custom colors during the run. Set
acceptable ΔE tolerances for the press (which might be slightly higher than lab tolerance
but still tight). For example, if your lab match was ΔE 0.5, you might allow up to ΔE 2 on
press, knowing some variation comes from press conditions. Many printers include spot
colors in their color bars or pull sheet samples periodically to measure. If you have a
modern press with a scanning spectro, program it for the spot color target. If not, a
handheld device and a standard operating procedure (SOP) for when/how to measure
(e.g., every 500 sheets or at every load change) can be implemented. This reduces
variability and ensures any drift is corrected promptly. The press team and the ink lab
team should speak the same language – e.g., both referencing Lab values and ΔE, not
just “it looks a bit off.” Introducing these quantitative checks might require a mindset
shift and training, but it will elevate consistency significantly.

6. Consider Automated Mixing for Efficiency: Evaluate the volume and frequency of your
custom color usage – if you find you’re mixing many batches per week or using
significant labor hours in ink prep, consider investing in an ink dispensing system or at
least a semi-automated scale setup. These systems can pay for themselves by reducing
waste and speeding up the mixing process. They also enable you to reuse leftover inks
efficiently. For instance, a dispenser can easily mix a fresh batch and incorporate 2 kg of
leftover from last time by adjusting the recipe, something that’s harder to do manually.
As noted, such systems bring accuracy to within 1 gram and essentially guarantee the
same result every time ( With 10 installations, Inkmaker seeking to expand | INKMAKER
SRL ). Even if a full dispenser is out of reach, a computer-connected scale that guides
manual dosing will reduce human error (Ink dispensing: the basics - GSE Dispensing).
The more you can automate the repetitive aspects of ink mixing, the more your skilled
staff can focus on the critical part – evaluating color and doing creative problem-solving
for tough matches – rather than spending time scooping ink on a scale. In a competitive
market, the faster you can turn around a custom color job (and with less waste), the
better your margins and customer satisfaction will be.

7. Leverage Supplier Support and Training: Don’t hesitate to use the resources available
from ink and equipment suppliers. Many vendors offer training sessions when you
purchase a spectrophotometer or software – take advantage of this to get your staff up
 to speed on proper usage. Ink suppliers often provide color training as well, teaching
about pigment properties and mixing techniques. Some will calibrate your formulation
software with their inks if you ask. As highlighted, partnering with a reliable ink supplier
can ensure you have consistent base materials and even formulation advice (Ink
dispensing: the basics - GSE Dispensing). If you encounter a particularly challenging
color (say a neon or a corporate color with specific requirements), consult with the ink
manufacturer’s lab – they might recommend a special pigment or pre-mixed ink.
Collaboration can streamline your process; for example, an ink company might supply a
concentrated base or a converter to add to your mix to achieve a certain shade or
lightfastness. Additionally, stay updated on new tools – for instance, newer spectros or
software updates might offer features (like better inter-instrument agreement or cloud-
based color libraries) that further improve consistency. Regularly calibrate and maintain
your instruments (e.g., annual recertification of the spectro’s calibration tile) as per
supplier guidelines to ensure ongoing accuracy.

8. Monitor and Continuously Improve: Implement a review system for your custom color
jobs. Keep track of any instances where a color match had issues and do a root cause
analysis – was it an instrument error, formula error, base ink lot variation, press issue,
etc.? By understanding any failures, you can refine your process. For example, you might
discover that a certain pigment in your set is prone to metamerism, leading you to
substitute it for a better one. Or you might find that your initial mixes were overshooting
because your base ink strength values in the software were slightly off – then you can
recalibrate those in the database. Continuously improving the accuracy of your color
database and the skills of your team will make each subsequent custom color easier. It
can also be valuable to monitor delta E trends on repeat jobs – if you see them creeping
up, it might indicate an issue (like a base ink batch variation or instrument drift) that you
can address proactively. Essentially, treat custom color production as a process to be
managed with the same rigor as any manufacturing process: set standards, measure
results, gather data, and refine.

By following these recommendations, an offset printer can build a robust custom color
capability. The initial effort and investment – perhaps buying a spectrophotometer, training
staff, organizing an ink room – are quickly offset by the benefits: faster match times, right-first-
time production, less ink waste, and the confidence to take on complex jobs. In a sense, your
goal is to make custom color printing as routine and predictable as printing standard Pantone
inks. With the right best practices and tools in place, even “one-of-a-kind” colors can be
handled in a systematic, repeatable way. This not only improves operational efficiency but also
opens up new opportunities (you can assure clients of exact brand color matching, handle
reprints seamlessly, and even differentiate by offering to create custom inks for them).

In conclusion, the key to formulating and reproducing special non-Pantone colors lies in
combining scientific approaches (measurements, formulas, data) with practical workflow
integration (procedures, training, and the right partnerships). The printing industry provides a
mature set of solutions – from spectrophotometers to ink software to dispensing systems – to
support this. Printers in India have access to all these technologies and should leverage them to
stay at par with global best practices. With these tools and methods, custom color matching
can transform from a headache into a hallmark of quality for an offset printing business,
ensuring vibrant, consistent results that keep customers coming back.

References and Sources

• HunterLab, Using a Spectrophotometer to Improve Color Quality and Performance of
Offset Inks – emphasizes the necessity of standard instruments in ink formulation and
how spectral data ensures consistency ( Using a Spectrophotometer to Improve Color
Quality and Performance of Offset Inks | HunterLab ) ( Using a Spectrophotometer to
Improve Color Quality and Performance of Offset Inks | HunterLab ).

• ZX Printer Blog, Explaining Spot Color Ink Mixing Techniques (2024) – compares
traditional visual ink mixing (prone to errors) with computer-based spectrophotometric
mixing, recommending the latter for accuracy (Explaining Spot Color Ink Mixing
Techniques) (Explaining Spot Color Ink Mixing Techniques). Provides tips like using
identical substrate for proofing and minimizing pigments in a mix (Explaining Spot Color
Ink Mixing Techniques) (Explaining Spot Color Ink Mixing Techniques).

• Screen Printing Magazine, Bring Order to Your Inkroom with Ink-Management Software –
details benefits of ink management software: formula retrieval, scaling, inventory
tracking, and integration with scales/dispensers (Bring Order to Your Inkroom with Ink-
Management Software - Screen Printing Mag) (Bring Order to Your Inkroom with Ink-
Management Software - Screen Printing Mag). Highlights that accurate records and
software are keys to repeatable colors (Bring Order to Your Inkroom with Ink-
Management Software - Screen Printing Mag).

• Castle Pierce (Packaging printer) – Custom Ink Formulation Services page – describes
an in-plant ink mixing workflow using INX’s services. Notes use of spectrophotometers,
drawdowns for color matching, and recorded ink formulations to guarantee future
repeatability (Custom Ink Formulation Services - Castle Pierce).

• GSE Dispensing Blog, Ink Dispensing: the Basics – explains how spot color formulas are
created and dispensed. Outlines three ways to get formulas (trial and error,
spectrophotometer with software, or ink supplier) (Ink dispensing: the basics - GSE
Dispensing). Stresses consistency of base inks (using same supplier/series for
accuracy) (Ink dispensing: the basics - GSE Dispensing). Describes manual vs
automated mixing, and how gravimetric dispensers achieve 1g accuracy and reduce
waste (Ink dispensing: the basics - GSE Dispensing) (Ink dispensing: the basics - GSE
Dispensing).

• PrintWeek India, With 10 installations, Inkmaker seeking to expand (2016) – reports on

Inkmaker’s ink dispensing systems in India. Notes that automatic dispensers offer
instant color reproduction and high accuracy, with benefits like stock reduction and
waste elimination ( With 10 installations, Inkmaker seeking to expand | INKMAKER SRL ).
Indicates Inkmaker’s local presence and that ink manufacturers often recommend
these systems to printers ( With 10 installations, Inkmaker seeking to expand |
INKMAKER SRL ).

• Pantone / X-Rite resources – various whitepapers and blogs (2020–2023) on digital ink
rooms and color management (specific citations not embedded due to access, but
content corroborates the need for a “digital workflow” with fewer steps and less waste,
aligning with points above).

• Industry supplier data sheets – e.g. hubergroup’s NewV CRS flyer (NewV CRS - The UV
ink mixing system for spot colours - Hubergroup) and product info, highlighting that
custom spot colors can be mixed with their system for optimal properties; and INX
International literature, showing how in-plant services can manage color for printers
(Castle Pierce example). These reinforce the solutions available from ink companies to
achieve custom colors.