Improving Color Precision in Paper Production with X-Rite Solutions

Achieving precise and consistent color on paper is a difficult process that involves managing various different aspects. The complexity begins with the raw materials, which include a diverse range of components:?

• Chemicals
• Fillers
• Dyes
• Pigments
• Optical brightening agents (OBAs)
• Other substances crucial for creating the pulp

Each of these elements introduces its own set of challenges in terms of compatibility and requires careful consideration to strike the right balance.

The pulp preperation is a critical phase where the composition of raw materials needs to be carefully controlled to ensure the desired color outcome. Any deviation in any of these components may lead to unexpected shifts in color. This makes it absolutely essential to monitor and adjust the formulation throughout the production process.

Apart from managing the raw materials, paper manufacturers must also factor in specific customer requirements and operational considerations. Customer specifications may vary widely, ranging from:

• Color accuracy
• Specific shades
• Gramage
• Finish types (glossy, matte, etc.)
• Chemical properties (wet strength, food save, …)
• Custom sizing or dimensions

Meeting these requirements demands a flexible and adaptable production process capable of accommodating diverse preferences without compromising efficiency or consistency.

Environmental factors can further complicate things. A dirty working environment can introduce contaminants that affect color and paper quality, while variations in retention can influence the chemical reactions responsible for color development. These external factors underscore the need for an agile and resilient production system capable of maintaining color accuracy despite unpredictable conditions.

The Role of Inline Color Measurement Systems?

To address these challenges and ensure the production of high-quality colored paper, an inline color measurement system becomes indispensable. This system should possess intelligence to assess color at critical checkpoints throughout the production line. By providing real-time feedback, such a system allows operators to promptly identify and rectify color shifts, preventing the production of defective or off-specification paper.?

This inline color measurement system should be smart, stable, reliable, and accurate for optimal performance. "Smart" implies the ability to adapt to changing conditions and learn from historical data to predict and prevent potential color variations. Stability and reliability are crucial for maintaining consistent color output over extended production runs, while accuracy ensures that the final product meets and exceeds the specified color standards.? Thus the instrument has to measure with good correlation to the laboratory measurements.?

X-Rite's Solution for Precise Color Management

This is where X-Rite, a leader in color management, measurement, and control since 1958, can help. X-Rite boasts an impressive range of products, including inline spectrophotometers designed for continuous process manufacturing lines. These instruments measure color in real time without interrupting production, enabling operators to make accurate adjustments and minimize errors.

For the pulp industry, X-Rite offers the ColorXRA 45 Pulp, a compact, 45°:0° inline spectrophotometer designed specifically for measuring color, whiteness, and brightness in thick pulp. Mounted in a stainless steel housing, it measures inline directly into the thick pulp, ensuring accuracy and identifying shifts before the pulp goes on the paper machine..

X-Rite provides ESWin Closed Loop Color Control (CLCC) software to improve the monitoring system, enabling continuous monitoring to detect color drift promptly and make adjustments before production goes out of tolerance.

This software manages color quality on continuous process production lines, displaying results and running automatic inline closed-loop color control on paper mill production lines, transitioning seamlessly from any start color to the target color in full automatic mode.

Benefits of X-Rite's Inline CLCC

There are many benefits of using this technology:

• Multicolor Handling: X-Rite's CLCC is uniquely capable of managing up to three colors simultaneously (plus OBAs in white paper). This involves using color-matching software to measure, compare with standards, and calculate corrections. The system is designed to address about 90% of deviations in one step, avoiding overshooting by adopting a conservative approach.
• Automatic Color Transitions: X-Rite's ESWin stands out as the only system capable of transitioning seamlessly from any color to another in fully automatic mode. This allows for quick start-ups or color changes with a simple button press, typically completed in half the time operators would need. The color adjustment occurs concurrently while operators are still fine-tuning the machines.
• Calibration Simplicity: X-Rite provides calibration data for the dyes, ensuring the customer receives a ready-to-use system.
• User-Friendly Operation: The software itself is designed for simplicity. Operating the system requires only a few buttons, and operator training can be completed in just one hour.?

Conclusion

In conclusion, achieving precise color in paper production is a complex process. Thankfully. X-Rite provides user-friendly solutions like inline spectrophotometers to measure the paper web and the ColorXRA 45 Pulp for accurate color measurement in thick pulp.

When integrated with our ESWin CLCC software, paper, and pulp companies can achieve continuous monitoring, swiftly detecting color drift. X-Rite's solutions simplify the production process, ensuring efficiency, accuracy, and seamless operations in colored paper manufacturing.