Causes of Color Differences and Recommended Solutions
In many cases, the produced color may slightly differ from the target color, even when using the formulation suggested by the software.
These discrepancies can arise from various factors, which are outlined below along with MEC’s recommended solutions for correcting and minimizing them.
1. Variations in the Production Process
When a factory operates multiple production lines, the same formulation may produce different color outcomes on each line.
These differences usually result from process variables such as temperature, pressure, mixing speed, or dispersion efficiency.
MEC Solution:
By analyzing spectral data from each production line, MEC helps identify process-related deviations and guides users in fine-tuning formulations to achieve consistent results across all lines.
2. Storage and Material Aging
Over time, base materials may undergo sedimentation or property changes due to storage conditions such as temperature, humidity, or light exposure.
These changes can lead to noticeable color shifts during production.
MEC Solution:
MEC enables users to track historical data and re-evaluate stored materials through re-measurement and recalibration, ensuring accuracy before use in new formulations.
3. Variation in Raw Material Suppliers
Purchasing raw materials from different suppliers—even with similar specifications—can result in minor variations in color strength or undertone.
MEC Solution:
The software allows easy database updating to include new raw material data, ensuring that future color predictions remain reliable and accurate.
4. Production at Different Times
Small variations in production conditions at different times—such as batch size, mixing order, or operator handling—can lead to slight color differences, even when using the same formula.
MEC Solution:
MEC supports QC data comparison over time, helping identify trends and adjust formulas automatically to maintain long-term color consistency.
5. Scale-Up from Laboratory to Production
Transitioning from laboratory scale to industrial production often introduces color variation due to changes in mixing equipment, shear rate, or dispersion uniformity.
MEC Solution:
By analyzing both lab and production data, MEC assists in scaling corrections, helping users adjust formulations to achieve the same color results in full-scale production.
6. Inaccurate Database Creation
Accurate color matching relies on a precise and well-calibrated database.
If the database is created with insufficient accuracy or inconsistent measurement conditions, color prediction errors may occur.
MEC Solution:
MEC includes built-in tools for database validation and recalibration, ensuring that all stored data represent real and consistent color behavior.
7. Minimizing Color Difference to the Smallest Possible Value
Even when the color difference (ΔE) is below 1.0, some customers may demand ultra-precise matching with a difference of less than 0.2.
MEC Solution:
Using its formulation correction module, MEC refines the formulation through iterative optimization to minimize ΔE to the lowest achievable level.
Conclusion
MEC Color Matching Software not only provides accurate initial formulations, but also offers advanced correction and optimization tools to eliminate color deviations caused by process, material, or environmental variations.
With MEC, you can achieve exceptional color accuracy and maintain consistent product quality, even under challenging production conditions.