DESC:FIELD
The present disclosure relates to the field of color matching. In particular, the present disclosure relates to a system and a method for synthesizing a target shade of ink.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Pantone Color system: The expression ‘Pantone Color system’ used in the context of this disclosure refers to but is not limited to, a proprietary color matching system that provides a standardized way to communicate and reproduce colors in various industries such as design, printing, textiles, and more. Each Pantone color is assigned a specific code, and these colors are typically defined in terms of their appearance on coated or uncoated paper.
Pantone shade: The expression “Pantone shade” used in the context of this disclosure refers to but is not limited to, a color shade identified by a specific code in the Pantone color system.
Color matching: The expression “Color matching” used in the context of this disclosure refers to but is not limited to, the process of ensuring consistency in the appearance of colors across different media, materials, or applications. This is crucial in design, printing, manufacturing, and various other industries where accurate color reproduction is essential. The goal is to achieve uniformity and precision, ensuring that a specific color looks the same, or as close as possible, across various platforms.
LAB: The expression “LAB” used in the context of this disclosure refers to but not limited to, a color space that represents colors independently of the device used to capture, display, or reproduce them. It was developed by the International Commission on Illumination (CIE) as a standard model for describing colors in a more perceptually uniform way. The LAB color space is widely used in color science, color correction, and industries where accurate and consistent color representation is crucial.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
India is a developing country with constant development across all the sectors in India. Likewise with the expanding demand by label, packaging, FMCG, and industrial segments to print the special unique colour has been increasing to make the required design effective, stand out from regular products, build a recognizable package, and strong brand identity and finally remain to sustain in the competitive market.
Accurate color printing plays a pivotal role in today's branding, packaging, and industrial sectors. Nevertheless, reproducing a special shade of color for packaging and achieving an exact match in terms of strength and properties can pose challenges for both printers and ink manufacturers. Companies involved in packaging typically procure the necessary or special shade of inks from manufacturers. However, the traditional color matching system is labor-intensive, leading to human errors that result in shade variations. Often, additional ink is required to attain the exact shade, leading to ink wastage. Moreover, the conventional process is slow due to the production delays caused by shade variations.
Furthermore, the traditional color matching process lacks consistency, resulting in different shades across various printers, materials, and lighting conditions. This inconsistency makes it challenging to achieve accurate and consistent color production. Additionally, the conventional color matching process is time-consuming, requiring extensive trial and error to attain the desired color. This, in turn, leads to increased lead times and reduced production efficiency.
There is, therefore felt a need for a system and a method to synthesize a desired shade of target ink that can alleviate the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a system to synthesize a target shade of ink that minimizes the human intervention to reduce errors and improve accuracy in reproducing special shades of target inks.
Another object of the present disclosure is to provide a system to synthesize a target shade of ink that can ensure precise matching of the desired shade, regardless of material or lighting conditions.
Yet another object of the present disclosure is to provide a system to synthesize a target shade of ink that can reduce ink wastage and consistent color reproduction.
Still another object of the present disclosure is to provide a system and a method to synthesize a target shade of ink that enables precise Pantone colour matching.
Another object of the present disclosure is to provide a system and a method that synthesizes consistently any Pantone or customized color using solvent-based inks, water-based inks, UV inks and UV LED inks.
Yet another object of the present disclosure is to provide a method for ink formulation that optimizes the use of pigments and other components, reducing the overall quantity of ink required to achieve the desired color strength and properties.
Another object of the present disclosure is to provide a system and a method to synthesize a target shade of ink that improves efficiency and reduces the time required to achieve the target shade of ink.
Yet another object of the present application is to provide a system and a method that reproduces inks of inbuilt formulations of Pantone or customised colors of solvent-based inks, water-based inks, UV inks and UV LED inks, that ensure consistency, improves efficiency and reduces the time required to achieve the target shade of ink during the print production process.
Another object of the present disclosure is to provide a method for ink formulation that ensures consistent color output and standardize color matching across different production batches, printers, and substrates.
Yet another object of the present application is to provide a system that ensures the adaptability to various printing technologies (e.g., offset, flexography, digital) and compatible with a wide range of substrates (e.g., paper, plastic, metal).
Still another object of the present disclosure is to provide a system and a method to synthesize a target shade of ink that optimizes ink usage, reducing wastage and improving cost-effectiveness.
Yet another object of the present disclosure is to provide a system and a method to synthesize a target shade of ink that create ink formulations to closely match the required color properties.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a system for synthesizing a target shade of ink. The system comprises a plurality of canisters, an input unit, an electronic control module, a measuring unit, a dispensing unit, a mixing unit, and a printing unit. Each of the canisters is configured to store inks of different shades with capacities ranging from 1lit to 10lit inks. The input unit is configured to receive an input command consisting of a Pantone shade to form a desired target shade of ink and is further configured to generate corresponding input signals for each shade of ink. The electronic control module is configured to be in communication with the input unit and each of the canisters. The electronic control module is configured to receive the input signals and is further configured to store the target shade of inks and corresponding predefined threshold color values. The measuring unit is configured to be in communication with electronic control module. The electronic control module is configured to transmit the input signals to the measuring unit to calculate a proportion of the ink of different shades from each of the canisters based on the input signals. The dispensing unit is configured downstream of the measuring unit and is further configured to be in communication with the electronic control module. The electronic control module is configured to dispense calculated proportions of ink of different shades from the dispensing unit. The mixing unit is configured to be in fluid communication with the dispensing unit to receive the dispensed inks of different shades and is further configured to mix the inks of different shades for a predefined time at a predefined speed and predefined temperature to synthesize a mixed shade of ink. The printing unit is configured to receive the synthesized mixed shade of ink and is further configured to print a patch using the mixed shade of ink on a substrate. The system is characterized whereby the electronic control module is configured to receive the printed patch from the printing unit, and the electronic control module is further configured to monitor deviations in color value(s) by comparing the printed patch to generate an alert if the deviation falls below or exceeds the corresponding predefined threshold color value(s).
In an embodiment, the electronic control module comprises a scanning unit, a repository unit, a comparator, and a processing unit. The scanning unit is configured to receive the printed patch and is further configured to scan the printed patch to determine a first color value. The repository unit is configured to be in communication with said scanning unit. The repository unit is configured to store the first color value, a target color value for said target shade of ink and the corresponding predefined threshold color value. The comparator is configured to be in communication with the repository unit and is further configured to compare the first color value with said target colour value to compute said deviation in color value(s). The processing unit is configured to be in communication with the comparator to receive the deviation in color value(s). The processing unit is further configured to generate an alert for the target shade ink if the deviation falls below or exceeds the predefined threshold color value.
In an embodiment, the plurality of canisters are configured to store inks selected from a group consisting of basic shades and process color inks such as PMS Black, PMS Green, PMS Orange16 C, PMS Orange 021, PMS Pink, PMS Process Blue, PMS Purple v.2, PMS Rubine Red, PMS Violet v.2 C, PMS Warm Red, PMS Red 032C, Yellow(PMS Yellow PY12 C), PMS Yellow, PMS Rhodamine Red, PMS Blue 072, PMS Reflex Blue, PMS Dark Blue, PMS Green, PMS Opaque White, PMS Transparent White, Process cyan, Process Magenta, Process Yellow, Gold, Silver and white.
In an embodiment, the viscosity of inks of different shades is ranging between 1cp to 6000cp, specific gravity of inks of different shades is ranging between 1.0 to 1.2 and solid content disposed in the inks is ranging between 5% to 100%.
In an embodiment, the canisters are configured to store inks of different basic shades and process colors inks selected from a group consisting of solvent-based ink, water-based ink, UV ink, UV LED ink, oil-based and plastisol-based ink or any combination thereof.
In an embodiment, the viscosity of the water-based, Solvent based, UV and UV LED inks lie in the range of 1cp to 6000cp, specific gravity of inks of different shades is ranging between 1.0 to 1.2 and solid content disposed in the inks is ranging between 5% to 100%.

In an embodiment, the dispensing unit is a piston based dispensing device having a plurality of piston pumps with capacities ranging from 1lit to 10lit.
In an embodiment, the electronic control module is configured with a set of machine learning rules to dispense varying proportions of the inks of different shades from the plurality of canisters (102a, 102b, 102c, 102d) by means of the dispensing unit.
In an embodiment, the dispensing unit is configured to be controlled manually and is further configured to manually dispense varying proportions of inks of the different shades.
In an embodiment, the electronic control module is selected from a group consisting of a spectrophotometer and a calorimeter or any combination thereof.
The present disclosure also envisages a method for synthesizing a target shade of ink. The method comprises the following steps:
• storing inks of different shades in the plurality of canisters;
• receiving, via the input unit, the input command having a Pantone shade corresponding to a desired target shade of ink;
• generating corresponding input signals for each shade of ink based on the input command;
• transmitting the input signals to the electronic control module, and storing the target shade of ink and a corresponding predefined threshold color value in the electronic control module;
• calculating, using the measuring unit in communication with the electronic control module, the proportion of ink of different shades from each of the canisters based on the input signals;
• dispensing the calculated proportions of ink of different shades via a dispensing unit controlled by the electronic control module;
• mixing the dispensed inks of different shades in a mixing unit for a predefined time, at a predefined speed, and at a predefined temperature for synthesizing a mixed shade of ink;
• printing, using a printing unit, a patch with the synthesized mixed shade of ink on a substrate;
• monitoring, using the electronic control module, deviations in color value(s) by comparing the printed patch with the predefined threshold color value(s); and
• generating an alert if the deviation in color value(s) falls below or exceeds the corresponding predefined threshold color value(s).
In an embodiment, the method further includes the following steps:
• scanning the printed patch to determine a first color value using a scanning unit;
• storing the first color value, the target color value for the target shade of ink, and the corresponding predefined threshold color value in a repository unit;
• comparing the first color value with the target color value using a comparator for computing the deviation in color value(s);
• generating the alert if the deviation in color value(s) exceeds or falls below the corresponding predefined threshold color value, using a processing unit; and
• uploading the formulation for the matched target shade in the system.
In an embodiment, the method for reproducing a pantone color or custom colors as per the method disclosed above, wherein the formulations are uploaded in the system, and reproduced during print production process. The method includes the following steps:
• storing, by the repository unit, the threshold values, the different Pantone shades, the pantone formulations for specific matched custom colors and the color values of the corresponding Pantone shades;
• providing, the plurality of canisters for storing inks of the different shades based on the pantone formulations;
• receiving, by the input unit, an input command to reproduce the desired target pantone shade or custom shade of ink;
• generating, by the input unit, an input signal based on the input command;
• transmitting the input signals to the electronic control module, and storing the color values of the desired target shade of ink;
• calculating, using the measuring unit in communication with the electronic control module, the proportion of inks of different shades from each of the canisters based on the input signals;
• dispensing the calculated proportions of ink of different shades via the dispensing unit controlled by the electronic control module;
• mixing the dispensed inks of different shades in the mixing unit for a predefined time, at a predefined speed, and at a predefined temperature for synthesizing the desired target shade of ink;
• printing, using the printing unit, a patch with the synthesized desired target shade of ink on a substrate; and
• monitoring, using the electronic control module, deviations in color value(s) by comparing the printed patch with the predefined threshold color value(s) to ensure consistency in the reproduced colors during printing operation.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A system and a method for synthesizing a target shade of ink, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a block diagram of a system for synthesizing target shade of ink in accordance with an of the present disclosure;
Figure 2A-2C illustrates a method steps for synthesizing target shade of ink in accordance with an of the present disclosure;
Figure 3 illustrates further method steps for synthesizing target shade of ink in accordance with an of the present disclosure;
Figure 4 illustrates an exemplary embodiment of a Pantone shade, color patches printed using water-based screen-printing ink, and corresponding color values;
Figure 5 illustrates an exemplary embodiment of a Pantone shade, color patches printed using water-based Flexo ink, and corresponding color values;
Figure 6 illustrates an exemplary embodiment of a Pantone shade, color patches printed using UV Flexo ink, and corresponding color values;
Figure 7 illustrates an exemplary embodiment of a Pantone shade, color patches printed using water based Gravure ink, shade and corresponding color values; and
Figure 8 illustrates an exemplary embodiment of a Pantone shade, color patches printed using UV LED Flexo ink, and corresponding color values.
LIST OF REFERENCE NUMERALS
100 - system for synthesizing a target shade of ink
102a, 102b, 102c, 102d - canisters
104 - input unit
106 - measuring unit
108 - dispensing unit
110 - mixing unit
112 - printing unit
114 - electronic control module
114a - scanning unit
114b – repository unit
114c - comparator
114d - processing unit
200 - method for synthesizing a target shade of ink
DETAILED DESCRIPTION
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units, and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
In the realm of packaging, labels, fast-moving consumer goods (FMCG), and industrial segments, the importance of producing visually captivating and uniquely branded products cannot be overstated. The ability to reproduce accurate and consistent colors on various substrates has become a cornerstone of effective branding and product differentiation. However, achieving such color accuracy has long been a challenge due to the limitations of traditional colour-matching methods.
Accurate color printing plays a pivotal role in today's branding, packaging, and industrial sectors. Nevertheless, reproducing a special shade of ink for packaging and achieving an exact match in terms of strength and properties can pose challenges for both printers and ink manufacturers. Companies involved in packaging typically procure the necessary or shade of inks from manufacturers. However, the traditional color matching system is labor-intensive, leading to human errors that result in shade variations. Often, additional ink is required to attain the exact shade, leading to ink wastage. Moreover, the conventional process is slow due to the production delays caused by shade variations.
Furthermore, the traditional color matching process lacks consistency, resulting in different shades across various printers, materials, and lighting conditions. This inconsistency makes it challenging to achieve accurate and consistent color production. Additionally, the conventional color matching process is time-consuming, requiring extensive trial and error to attain the desired color. This, in turn, leads to increased lead times and reduced production efficiency.
To address the drawbacks of the existing conventional system, the present disclosure envisages a system and method for synthesizing a target shade of ink. The system for synthesizing a target shade of ink (hereinafter may be referred to as a system 100), for the sake of brevity.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Figure 1 illustrates a block diagram of a system for synthesizing a target shade of ink. The system (100) for synthesizing a target shade of ink offers a highly accurate and automated solution, configured to synthesize custom ink shades on demand. The system integrates advanced control, measurement, and mixing technologies to ensure that each synthesized shade closely matches the target color, whether it be a Pantone reference or a custom color specification. The system (100) for synthesizing a target shade of ink is a comprehensive assembly, configured to deliver precise color matching through a series of interconnected components. The system's primary function is to store various primary inks, calculate and dispense the correct proportions, mix these inks, and then verify the synthesized color against the desired target shade. Therefore, the system 100 comprises a plurality of canisters 102a, 102b, 102c, 102d, an input unit 104, a measuring unit 106, a dispensing unit 108, a mixing unit 110, a printing unit 112 and an electronic control module 114. The components of the system 100 are in communication with each other for synthesizing the target shade of the ink.
The system begins with the plurality of canisters, each configured to store inks of different shades and designed to store inks with capacities ranging from 1lit to 10lit inks. Each of the canisters accommodate a wide range of primary inks, including but not limited to basic shades and process colors such as C,M,Y,K colors. The basic primary shades includes Warm Red, Reflex Blue, Orange, Rhodamine red, Yellow, Dense Black, Red, Orange, Violet, Blue, Rubine Red, Purple, Green, and other commonly used inks in the printing industry.
In an embodiment, the inks stored in the canisters may vary in viscosity ranging between 1cp to 6000cp, specific gravity of inks of different shades is ranging between 1.0 to 1.2 and solid content disposed in the inks is ranging between 5% to 100%. , thereby allowing for a versatile color synthesis process.
In an embodiment, the canisters store fourteen basic shades of colors and four process colors.
In an embodiment, the plurality of canisters 102a, 102b, 102c, 102d store inks of different shades including PMS Black, PMS Green, PMS Orange16 C, PMS Orange 021, PMS Pink, PMS Process Blue, PMS Purple v.2, PMS Rubine Red, PMS Violet v.2 C, PMS Warm Red, PMS Red 032C, Yellow (PMS Yellow PY12 C), PMS Yellow, PMS Rhodamine Red, PMS Blue 072, PMS Reflex Blue, PMS Dark Blue, PMS Green, PMS Opaque White, PMS Transparent White, Process cyan, Process Magenta, Process Yellow, Gold, Silver and white.
In an embodiment, the canisters 102a, 102b, 102c, 102d store different basic shades of inks and process colors inks consisting of solvent-based ink, water-based ink, UV ink, UV LED ink, oil-based and plastisol-based ink, or any combination thereof.
In an embodiment, the viscosity of water-based ink, Solvent-based ink, UV and UV LED inks is ranging between 1cp to 6000cp, specific gravity of inks of different shades is ranging between 1.0 to 1.2 and solid content disposed in the inks is ranging between 5% to 100%.
Further, the input unit is responsible for receiving input commands, typically in the form of a Pantone shade code, that specifies the desired target shade of ink. Upon receiving the command, the input unit generates corresponding input signals for each shade of ink that needs to be combined. The input unit is integral to guiding the subsequent processes as it translates the target shade into actionable data. The input unit 104 of the system 100 includes a display screen and a plurality of buttons. The input unit is configured to receive the input command from an operator. The operator may use the plurality of buttons and the display screen to provide input command. The input command consists of a Pantone shade to form the desired the target ink shade.
The electronic control module (ECM), is in constant communication with the input unit, the canisters, and other system components. The ECM receives the input signals, stores the target shade information along with predefined threshold color values, and manages the overall synthesis process. The ECM is configured to communicate with various modules within the system, ensuring that the correct proportions of inks are dispensed, mixed, and tested.
In an embodiment, the ECM is selected from a group consisting of a spectrophotometer and a calorimeter and any combination thereof. The spectrophotometer is configured to record the absorbance or transmittance value of the inks at various wavelengths within the visible spectrum, usually in the range of 380nm-780nm.
In a preferred embodiment, the ECM houses advanced functionalities, including a scanning unit (114a), a repository unit (114b), a comparator (114c), and a processing unit (114d). These sub-units work together to scan the printed patch, store relevant data, compare measured color values with target values, and generate alerts if deviations occur beyond acceptable thresholds.
Further, the measuring unit receives the input signals from the ECM and calculates the necessary proportions of ink from each canisters to synthesize the target shade. The precise measurement of ink proportions is critical, as it directly affects the accuracy of the synthesized shade. The measuring unit uses sophisticated algorithms, stored in the ECM and calibration data to ensure that each proportion aligns with the target requirements.
The dispensing unit 108 is positioned downstream of the measuring unit, the dispensing unit (108) comprises a piston-based dispensing device equipped with multiple piston pumps. The ECM controls the dispensing unit to release the calculated ink proportions into the mixing unit. The dispensing unit can be operated automatically through the ECM or manually, providing flexibility in its operation. For automatic operation, the ECM can be configured with the set of machine learning rules to optimize the dispensing process, thereby enhancing the accuracy of the ink synthesis.
In an embodiment, the dispensing unit is configured with a set of machine learning rules to auto-dispense varying proportions of the inks of different shades from said plurality of canisters 102a, 102b, 102c, 102d.
Further, the mixing unit is where the actual synthesis of the target shade takes place. The mixing unit receives the dispensed inks from the dispensing unit and mixes them for a predefined time, at a specified speed, and under controlled temperature conditions. These parameters are pre-set and monitored to ensure consistent mixing quality, which is essential for achieving a uniform shade.
After the inks are mixed from each of the canister, the resulting shade is transferred to the printing unit, which prints a patch of the synthesized ink on a substrate. The printed patch serves as a physical representation of the synthesized shade and is necessary for the final verification step. The printed patch is scanned by the ECM's scanning unit (114a) to determine the first color value.
In an embodiment, the mixing unit 110 includes a container, a heating means and a stirrer placed in the container. The container of the mixing unit 110 receives inks of the different shades from the dispensing unit 108. The heating means is connected to the container to heat the inks received in the container. The stirrer is configured to stir the inks of the different shades at a predefined speed, predefined heating rate and for predefined time to synthesize a homogenous ink.
Further, once the patch is printed, the ECM compares the first color value obtained from the scanning unit with the stored target color value. Using the comparator (114c), any deviation between the synthesized shade and the target shade is calculated. If this deviation falls outside the predefined threshold values, the processing unit (114d) generates an alert. This mechanism ensures that any inconsistencies in color are promptly identified and addressed, allowing for adjustments in the synthesis process to maintain the desired color accuracy. If the deviation is within the acceptable limit, then the ECM records the formulation of the synthesized target ink which is the target ink.
Additionally, the machine learning capabilities of the system facilitate refining and optimizing the ink dispensing process based on historical data and ongoing performance. This leads to improvements in the accuracy and efficiency of the color synthesis process over time.
In an embodiment, the system 100 is used for color matching in, narrow web flexo printing, wide web flexo printing, Gravure printing and screen-printing process.
Further, the present disclosure also envisages a method 200 for synthesizing a target shade of the ink. Figure 2 illustrates a method for synthesizing a target shade of the ink. The method 200 for synthesizing ink of the target shade, comprises the following steps:
• At step 202, the method 200 includes, storing inks of different shades in a plurality of canisters (102a, 102b, 102c, 102d);
• At step 204, the method 200 includes, receiving, via an input unit (104), an input command having a Pantone shade corresponding to a desired target shade of ink;
• At step 206, the method 200 includes, generating corresponding input signals for each shade of ink based on said input command ;
• At step 208, the method 200 includes, transmitting said input signals to an electronic control module (114), and storing the target shade of ink and a corresponding predefined threshold color value in said electronic control module (114);
• At step 210, the method 200 includes, calculating, using a measuring unit (106) in communication with the electronic control module (114), the proportion of ink of different shades from each of the canisters (102a, 102b, 102c, 102d) based on said input signals;
• At step 212, the method 200 includes, dispensing the calculated proportions of ink of different shades via a dispensing unit (108) controlled by said electronic control module (114);
• At step 214, the method 200 includes, mixing the dispensed inks of different shades in a mixing unit (110) for a predefined time, at a predefined speed, and at a predefined temperature for synthesizing a mixed shade of ink;
• At step 216, the method 200 includes, printing, using a printing unit (112), a patch with said synthesized mixed shade of ink on a substrate;
• At step 218, the method 200 includes, scanning said printed patch to determine a first color value using a scanning module (114a);
• At step 220, the method 200 includes, storing the first color value, the target color value for the target shade of ink, and the corresponding predefined threshold color value in a repository unit (114b);
• At step 222, the method 200 includes, monitoring, using said electronic control module (114), deviations in color value(s) by comparing the printed patch with the predefined threshold color value(s);
• At step 224, the method 200 includes, generating an alert if said deviation in color value(s) falls below or exceeds the corresponding predefined threshold color value(s); and
• At step 226, the method 200 includes, uploading the formulation for the matched target shade in the system
Now, the proposed idea will be described through non-limiting experiment.
In a preferred embodiment, the method for reproducing a pantone color or custom colors as per the method disclosed above, wherein the formulations are uploaded in the system, and reproduced during print production process. The method includes the following steps:
• storing, by the repository unit, the threshold values, the different Pantone shades, the pantone formulations for specific matched custom colors and the color values of the corresponding Pantone shades;
• providing, the plurality of canisters (102a, 102b, 102c, 102d) for storing inks of the different shades based on the pantone formulations;
• receiving, by the input unit (104), an input command to reproduce the desired target pantone shade or custom shade of ink;
• generating, by the input unit (104), an input signal based on the input command;
• transmitting the input signals to the electronic control module (114), and storing the color values of the desired target shade of ink;
• calculating, using the measuring unit (106) in communication with the electronic control module (114), the proportion of inks of different shades from each of the canisters (102a, 102b, 102c, 102d) based on the input signals;
• dispensing the calculated proportions of ink of different shades via the dispensing unit (108) controlled by the electronic control module (114);
• mixing the dispensed inks of different shades in the mixing unit (110) for a predefined time, at a predefined speed, and at a predefined temperature for synthesizing the desired target shade of ink;
• printing, using the printing unit (112), a patch with the synthesized desired target shade of ink on a substrate; and
• monitoring, using the electronic control module (114), deviations in color value(s) by comparing the printed patch with the predefined threshold color value(s) to ensure consistency in the reproduced colors during printing operation.
Experimental Procedure
The following experimental procedure outlines the method steps used to synthesize a target shade of ink. The process involves various instruments, including a printing device (ink proofer), UV dryer, light box (viewing booth), measuring module (electronic weighing balance), dispensing module, and a Pantone Guide. The experimental conditions are carefully controlled to ensure accuracy and reproducibility of results.
The color matching of Pantone inks typically requires controlled lab conditions to ensure the accuracy of the experiments. The lab conditions and considerations are as follows:
Lighting: Consistent and standardized lighting conditions are crucial for accurate color matching. A light booth simulating D65 daylight with a color temperature of 6500K is used to ensure uniform lighting.
Viewing Angle: The viewing angle affects color accuracy, contrast, and brightness. For this experiment, a 45-degree viewing angle is used to minimize metamerism, a phenomenon where colors appear to match under one light source but not another.
Ink and Substrate: The ink and substrate (e.g., paper or material) used are identical to those in the Pantone Swatch to maintain consistency.
Temperature and Humidity: Lab conditions are stabilized to maintain consistent temperature and humidity, as variations can affect ink drying and color appearance.
Calibration: Instruments, particularly the spectrophotometer, are calibrated regularly to ensure precise color measurements.
Color Standards: Official Pantone Color Guides or swatch books, in good condition without fading, are used as references for color matching.
Ink Mixing: Ink mixing follows Pantone’s recommended formulas and procedures to achieve the desired color.
Observers: Color matching is performed by trained personnel with expertise in color management and verified color vision.
Documentation: Detailed records of the ink mixing process, including recipes, measurements, and any adjustments, are maintained.
Quality Control: Quality control checks are implemented to verify color accuracy and consistency throughout the process.
Viewing Booth Specifications: The viewing booth, an essential tool for accurate color assessment, replicates standardized lighting conditions. Equipped with light sources such as D65 daylight (6500K), the booth provides uniform illumination across the interior to minimize light intensity variations. Regular calibration ensures consistent lighting.
The booth’s walls are painted with Munsell neutral gray, providing a controlled, non-reflective environment that reduces color bias. The matte finish minimizes glare and reflections, preventing distortions in color perception.
The experimental conditions of the viewing booth are mentioned below.
The viewing booth, also known as a light booth or color viewing booth, is an essential tool in color management for accurate color assessment and matching. The viewing booths are equipped with specific light sources that replicate standardized lighting conditions. For color matching, the primary light source used is typically D65 daylight (6500K) for graphic and printing applications. Further, the viewing booth is used to provide uniform illumination across the interior, minimizing variations in light intensity. This ensures that the entire sample being assessed receives the same lighting conditions. The viewing booth is calibrated regularly.
The color of the walls of the viewing booth plays an important role. The gray color for the walls of a viewing booth should be used for maintaining a controlled lighting environment. The neutral gray colur should be used to create a neutral and non-reflective background that doesn’t introduce any color bias into the viewing environment. Munsell neutral gray, is used for viewing booth walls. This value provides a suitable balance between darkness and reflectance. The Munsell is a color notation system that defines colors based on hue, value(lightness), and chroma (saturation). The value of the Gray should be chosen to ensure that it contrasts well with the colors being assessed without being too dark or too light. A mid-range gray helps prevent visual fatigue and allows colors to be evaluated accurately. The walls should have a matte or non-reflective finish to minimize glare and reflections that could affect color perception. Glossy or shiny surfaces can distort the appearance of colors.
For the new color shade, select the nearest pantone shade, dispense the ink in minimum quantity from 10gm to 100gm to avoid the wastage of the ink during color matching. As per the standard operating procedure, dispense the ink, mix the dispensed ink and take a print out with the help of printing unit. The electronic measuring unit which comprises the spectrophotometric, the processing unit of spectrophotometer configured to be in communication with the comparator to receive the deviation in color value. The processing unit is further configured to generate an alert for the target shade ink if said deviation falls below the predefined threshold color value.
The method steps for experimentation are as follows:
Step 1: Initially, a set of basic colors is selected. These colors include process colors (C, M, Y, K) with basic 14 shades such as Warm Red, Reflex Blue, Orange, Rhodamine red, Yellow, Dense Black, Red, Orange, Violet, Blue, Rubine Red, Purple, Green.
Step 2: The color target or specifications for the reference color from the Pantone Guide is selected.
Step 2: The substrate on which the ink will be printed is selected.
Step 3: The spectrophotometer or colorimeter is calibrated.
Step 4: The base ink that is close to the target color is selected.
Step 5: The color of the base ink is measured using the spectrophotometer and recorded for reference.
Step 6: Formulation software or manual calculations are used to determine the adjustments needed in ink formulation. Gradually other special colors are added to the base ink to reach the desired color.
Step 7: The final ink formulation is recorded for further experiments.
Step 8: The final formulations of the ink color for the water-based, UV, and LED inks are fed into the dispenser.
Step 9: The quantity of ink to be dispensed is inputted into the dispensing unit. The dispensing unit dispenses the measured amounts of each ink into a mixing container, The weighing scale weighs the ink dispensed through the nozzle of the dispenser.
Step 10: The dispensed ink in the container which will be placed on the weighting balance.
Step 11: The ink is mixed and provided to the printing device for printing a patch.
Step 12: A spectrophotometer is used for the measurement of LAB information. The LAB information of the printed patch is measured and compared with the LAB information of the reference Pantone shade. The spectrophotometer records the absorbance or transmittance value at various wavelengths within the visible spectrum (usually in the range of 380-780nm). The comparison is also done using color difference formulas ?E CIELab, ?E CIE94, and ?E CIE2000. These formulas take into account differences in lightness (L), Chroma (a and b values), and hue (C and h values) to quantity the color difference. For this experiment, ?E was calculated by using ?E 2000 equation.
The smaller ?E value indicates a smaller color difference between the reference and the sample, while a larger value indicates a larger difference. The threshold for an acceptable color difference can vary depending on the application. In this experiment, the threshold value considered as ?E below 0.5 value.
The difference between the LAB information of printed patch and Pantone shade is determined and shown by Figure 4- Figure 8.
Figure 4 illustrates a color patches synthesized using water-based screen-printing ink, a Pantone shade and corresponding color values.
Figure 5 illustrates color patches synthesized using water based Flexo ink, a Pantone shade and corresponding color values.
Figure 6 illustrates color patches synthesized using UV Flexo ink, a Pantone shade and corresponding color values.
Figure 7 illustrates color patches synthesized using water-based Gravure ink, a Pantone shade and corresponding color values.
Figure 8 illustrates color patches synthesized using UV LED Flexo ink, a Pantone shade and corresponding color values.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, a system for synthesizing target shade of ink and a method thereof that:
• minimizes the human intervention to reduce errors and improve accuracy in reproducing special shades of target inks, this will enhance consistency and reliability in color reproduction across different printers and production environments;
• ensures precise matching of the desired shade, regardless of material or lighting conditions, this eliminates the need for multiple trials and adjustments, thereby reducing ink wastage and production delays.;
• enables precise Pantone colour matching;
• synthesizes consistently any Pantone or customized color shade using solvent-based inks, water-based inks, UV inks and UV LED inks;
• improves efficiency and reduces the time required to achieve the desired shade of color;
• optimizes ink usage, reducing wastage and improving cost-effectiveness;
• adopts standardized color profiles to ensure consistency across different printers, materials, and lighting conditions;
• optimizes the use of pigments and other components, reducing the overall quantity of ink required to achieve the desired color strength and properties;
• streamlines the production process, reduce lead times, and improve overall production efficiency by predicting the exact combination of pigments and additives required for each specific color match;
• creates ink formulations to closely match the required color properties.
• provides highly accurate weight measurement of ink;
• saves time of color matching process;
• ensures consistent color output and standardize color matching across different production batches, printers, and substrates, this achieves the uniformity in color appearance, enhancing brand identity and product differentiation in the market.;
• ensures the adaptability to various printing technologies (e.g., offset, flexography, digital) and compatible with a wide range of substrates (e.g., paper, plastic, metal); and
• reduces need of the rework, and environmental cost.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A system (100) for synthesizing a target shade of ink, said system (100) comprising:
• a plurality of canisters (102a, 102b, 102c, 102d), each of said canisters configured to store inks of different shades, with capacities ranging from 1lit to 10lit inks;
• an input unit (104) configured to receive an input command consisting of a Pantone shade to form a desired target shade of ink and further configured to generate corresponding input signals for each shade of ink;
• an electronic control module (114) configured to be in communication with said input unit (104) and each of said canisters(102a, 102b, 102c, 102d), said electronic control module (114) configured to receive said input signals and further configured to store said target shade of ink and a corresponding predefined threshold color value;
• a measuring unit (106) configured to be in communication with electronic control module (114), said electronic control module (114) configured to transmit said input signals to said measuring unit (106) to calculate a proportion of the ink of different shades from each of said canisters (102a, 102b, 102c, 102d) based on said input signals;
• a dispensing unit (108) configured downstream of said measuring unit (106) and further configured to be in communication with said electronic control module (114), said electronic control module (114) configured to dispense calculated proportions of ink of different shades from said dispensing unit (108);
• a mixing unit (110) configured to be in fluid communication with said dispensing unit (108), said mixing unit (110) configured to receive the dispensed inks of different shades and further configured to mix the inks of different shades for a predefined time at a predefined speed and at a predefined temperature to synthesize a mixed shade of ink; and
• a printing unit (112) configured to receive said synthesized mixed shade of ink and further configured to print a patch using said mixed shade of ink on a substrate,
wherein said system is characterized whereby said electronic control module (114) is configured to receive said printed patch from said printing unit (112), and said electronic control module (114) is further configured to monitor deviations in color value(s) by comparing said printed patch to generate an alert if said deviation falls below or exceeds the corresponding predefined threshold color value(s).
2. The system (100) as claimed in claim 1, wherein said electronic control module (114) includes,
a. a scanning unit (114a) is configured to receive said printed patch and is further configured to scan said printed patch to determine a first color value;
b. a repository unit (114b) is configured to be in communication with said scanning unit (114a), said repository unit is configured to store the first color value, a target color value for said target shade of ink and the corresponding predefined threshold color value;
c. a comparator (114c) is configured to be in communication with said repository unit (114b), said comparator (114c) is configured to compare said first color value with said target colour value to compute said deviation in color value(s); and
d. a processing unit (114d) is configured to be in communication with said comparator (114c) to receive said deviation in color value(s), said processing unit is further configured to generate said alert for said target shade ink if said deviation falls below or exceeds the corresponding predefined threshold color value.
3. The system (100) as claimed in claim 2, wherein said electronic control module (114) is selected from a group consisting of a spectrophotometer and a calorimeter and any combination thereof.
4. The system (100) as claimed in claim 1, wherein said plurality of canisters (102a, 102b, 102c, 102d) are configured to store inks selected from a group consisting of basic shades and process color inks such as PMS Black, PMS Green, PMS Orange16 C, PMS Orange 021, PMS Pink, PMS Process Blue, PMS Purple v.2, PMS Rubine Red, PMS Violet v.2 C, PMS Warm Red, PMS Red 032C, Yellow(PMS Yellow PY12 C), PMS Yellow, PMS Rhodamine Red, PMS Blue 072, PMS Reflex Blue, PMS Dark Blue, PMS Green, PMS Opaque White, PMS Transparent White, Process cyan, Process Magenta, Process Yellow, Gold, Silver and white.
5. The system (100) as claimed in claim 4, wherein the viscosity of inks of different shades is ranging between 1cp to 6000cp, specific gravity of inks of different shades is ranging between 1.0 to 1.2 and solid content disposed in the inks is ranging between 5% to 100%.
6. The system (100) as claimed in claim 1, wherein said canisters (102a, 102b, 102c, 102d) are configured to store inks of different basic shades and process colors inks selected from a group consisting of solvent-based ink, water-based ink, UV ink, UV LED ink, oil-based and plastisol-based ink or any combination thereof.
7. The system (100) as claimed in claim 6, wherein the viscosity of water-based ink, Solvent-based ink, UV and UV LED inks is ranging between 1cp to 6000cp, specific gravity of inks of different shades is ranging between 1.0 to 2.5g/ml and solid content disposed in the inks is ranging between 5% to 100%.
8. The system (100) as claimed in claim 1, wherein said dispensing unit (108) is a piston based dispensing device having a plurality of piston pumps.
9. The system (100) as claimed in claim 8, wherein said electronic control module (114) is configured with a set of machine learning rules to dispense varying proportions of the inks of different shades from said plurality of canisters (102a, 102b, 102c, 102d) by means of said dispensing unit (108).
10. The system (100) as claimed in claim 8, wherein said dispensing unit (108) is configured to be controlled manually and is further configured to manually dispense varying proportions of inks of the different shades by means of said dispensing unit (108).
11. A method (200) for synthesizing a target shade of ink, said method comprising the following steps:
• storing inks of different shades in a plurality of canisters (102a, 102b, 102c, 102d);
• receiving, via an input unit (104), an input command having a Pantone shade corresponding to a desired target shade of ink;
• generating corresponding input signals for each shade of ink based on said input command;
• transmitting said input signals to an electronic control module (114), and storing the target shade of ink and a corresponding predefined threshold color value in said electronic control module (114);
• calculating, using a measuring unit (106) in communication with the electronic control module (114), the proportion of ink of different shades from each of the canisters (102a, 102b, 102c, 102d) based on said input signals;
• dispensing the calculated proportions of ink of different shades via a dispensing unit (108) controlled by said electronic control module (114);
• mixing the dispensed inks of different shades in a mixing unit (110) for a predefined time, at a predefined speed, and at a predefined temperature for synthesizing a mixed shade of ink;
• printing, using a printing unit (112), a patch with said synthesized mixed shade of ink on a substrate;
• monitoring, using said electronic control module (114), deviations in color value(s) by comparing the printed patch with the predefined threshold color value(s); and
• generating an alert if said deviation in color value(s) falls below or exceeds the corresponding predefined threshold color value(s).
12. The method (200) as claimed in Claim 11, further includes:
• scanning said printed patch to determine a first color value using a scanning unit (114a);
• storing the first color value, the target color value for the target shade of ink, and the corresponding predefined threshold color value in a repository unit (114b);
• comparing the first color value with the target color value using a comparator (114c) for computing the deviation in color value(s);
• generating the alert if said deviation in color value(s) exceeds or falls below the corresponding predefined threshold color value, using a processing unit (114d); and
• uploading the formulation for the matched target shade in the system.
13. A method for reproducing a pantone color or custom colors as per the method (200) as claimed in claim 12, wherein said formulations are uploaded in the system, and reproduced during print production process, said method includes the following steps:
• storing, by said repository unit, the threshold values, the different Pantone shades, said pantone formulations for specific matched custom colors and the color values of the corresponding Pantone shades;
• providing, said plurality of canisters (102a, 102b, 102c, 102d) for storing inks of the different shades based on said pantone formulations;
• receiving, by said input unit (104), an input command to reproduce said desired target pantone shade or custom shade of ink;
• generating, by said input unit (104), an input signal based on said input command;
• transmitting said input signals to said electronic control module (114), and storing the color values of the desired target shade of ink;
• calculating, using said measuring unit (106) in communication with the electronic control module (114), the proportion of inks of different shades from each of said canisters (102a, 102b, 102c, 102d) based on said input signals;
• dispensing the calculated proportions of ink of different shades via said dispensing unit (108) controlled by said electronic control module (114);
• mixing the dispensed inks of different shades in said mixing unit (110) for a predefined time, at a predefined speed, and at a predefined temperature for synthesizing the desired target shade of ink;
• printing, using said printing unit (112), a patch with the synthesized desired target shade of ink on a substrate; and
• monitoring, using said electronic control module (114), deviations in color value(s) by comparing the printed patch with the predefined threshold color value(s) to ensure consistency in the reproduced colors during printing operation.
Dated this 4th day of September, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT