What’s the difference between spot color and process color in flexo printing? | Keshenglong&Shinko Guide

What’s the Difference Between Spot Color and Process Color in Flexo Printing?

Flexo printing professionals frequently encounter the decision between spot color and process color. Understanding their differences is key for achieving optimal print quality, color consistency, and production cost control.

Spot Color in Flexo Printing

- Definition:

Spot color uses pre-mixed inks for each specific color in a design.

- Color Matching:

Delivers accurate and repeatable color consistency, ideal for brand logos.

- Ink Use:

Uses Pantone Matching System (PMS) or custom-mixed ink formulas.

- Applications:

Best for jobs requiring solid, consistent colors or fewer color changes.

- Advantages:

- Precise brand color reproduction

- Superior opacity on various substrates

- Fewer issues with color variations between print runs

- Limitations:

- Increased ink inventory

- Additional wash-up and setup time for each color

- Higher cost for multi-color images

*Source: (https://www.pantone.com/articles/technical/spot-vs-process)*

Process Color in Flexo Printing

- Definition:

Process color builds images using CMYK (Cyan, Magenta, Yellow, Black) inks, printed in a layered dot pattern.

- Color Creation:

Simulates a broad range of colors by mixing four inks in precise percentages.

- Applications:

Suited for photographic images, full-color graphics, and complex illustrations.

- Advantages:

- Efficient for prints with a wide color gamut

- Requires just four ink stations for most jobs

- Lower overall ink inventory needs

- Limitations:

- Less accurate reproduction of specific brand colors

- Possible color shifts due to ink density or substrate variation

- Visible dot patterns (rosettes) at close inspection

*Source: (https://www.flexography.org/publications/flexo-magazine/process-color/)*

Key Comparison Points

Color Accuracy

- Spot Color: Superior for exact color replication.

- Process Color: Great for gradients and photos, but limited for spot-matching.

Print Run Efficiency

- Spot Color: Faster for single-color or short runs.

- Process Color: More efficient for large, multi-color print jobs.

Cost Impact

- Spot Color: Higher per-job cost with many colors.

- Process Color: Economical for full-color images, especially at scale.

Conclusion

Both spot color and process color have distinct roles in flexo printing. Professionals should choose based on project requirements—brand color fidelity favors spot colors, while complex images and cost-efficiency favor process color. A clear understanding of these differences will help in making informed decisions for workflow, cost management, and client satisfaction.

For authoritative resources, refer to (https://www.flexography.org/) and (https://www.pantone.com/).

*Stay informed with Keshenglong&Shinko—your partner in advanced flexo printer solutions.*