Building a Consistent, Color-Managed Flexographic Print Workflow

Case Study Overview

In August 2025, a startup flexographic printing company based in Davao City, in the southern part of the Philippines, approached LabHue Color seeking a print workflow that would enable the company to rely on technology to manage print output according to recognized color standards, whether in-house or international. The goal was consistent and repeatable color regardless of the printing method used.

Objective

The client required a professional print workflow solution that would:

• Ensure color consistency across all print outputs.
• Follow recognized in-house or international color standards, particularly the Idealliance G7 methodology for print calibration and color consistency.
• Maintain repeatable print quality regardless of printer used.
• Improve workflow efficiency through technology-driven solutions.
• Support reliable and high-quality flexographic printing operations.

Proposed Solution

The initial proposed solution combined an Epson SC-S9130 prototyping printer with GMG ColorProof and GMG OpenColor software.

LabHue Color provided a print workflow system designed to streamline production processes while maintaining accurate color management standards on both the actual press and the Epson SC-S9130, using actual press materials.

The solution focused on:

1. Standardized color management processes.
2. Printer calibration and profiling.
3. Consistent print reproduction across devices.
4. Similar press materials across both flexo and digital printers.
5. Reliable quality control measures.
6. Efficient workflow integration for daily operations.

Workflow Upgrade

After a few months of using the initially proposed solution, the company opted to further upgrade its print workflow by acquiring GMG ColorServer and Bodoni PressSIGN. These additional solutions enhanced its color management capabilities, automated print standardization processes, and improved overall print quality verification and consistency.

The upgraded workflow allowed the company to:

• Achieve more advanced color conversion and optimization.
• Improve process automation for print production.
• Strengthen quality assurance and print verification.
• Increase consistency across different printing devices and substrates.
• Enhance compliance with international printing standards.

From Proofs to Press Output

From digital proofs to actual press prints, color consistency was successfully maintained across production. The images demonstrate accurate color reproduction through proper calibration, proof verification, and print standardization processes.

Using G7 methodology, the team achieved a stable grey balance, ensuring that neutral tones remained visually balanced throughout the workflow. By carefully controlling and measuring the required CMY and K density values, the printed output closely matched the approved proofs, minimizing color shifts between proofing and final production.

The use of spectrodensitometers, color bars, and print quality checks verified that the press output met target densities and G7 standards. This process supports predictable, repeatable, and high-quality color results—from proof to final print.

Softproofing Implementation

Another key highlight during the installation was the implementation of softproofing using GMG ColorPlugin together with a color-manageable BenQ monitor. This solution enabled accurate on-screen color visualization and evaluation prior to print production, helping improve color consistency, reduce proofing costs, and streamline approval processes.

The softproofing workflow allowed the company to:

• Achieve more accurate on-screen color representation.
• Reduce dependence on physical proofs.
• Improve collaboration and approval efficiency.
• Enhance color confidence before final print production.
• Support standardized and color-managed viewing conditions.

Ambient Light Calibration and Viewing Environment Standardization

As part of the installation and color management implementation, the company’s prepress, press, R&D, and meeting rooms underwent an ambient light correction and viewing environment standardization procedure. This process was performed using the X-Rite i1Pro 3 device together with an ambient lighting software solution.

The ambient light calibration procedure ensured that viewing conditions across departments were aligned with color management best practices and industry standards, particularly supporting accurate visual evaluation under controlled D50/D65 lighting environments.

Key benefits of the implementation included:

• Standardized lighting conditions across critical work areas.
• Improved color evaluation accuracy.
• Reduced visual color discrepancies caused by inconsistent lighting.
• Enhanced softproofing and print verification reliability.
• Better alignment with Idealliance G7 color management objectives.

Technology Partners and Implementation Team

The solutions provided were managed and supported by companies from LabHue Color, GMG Color, and TLab Color.

The successful implementation of the print workflow and color management system was led by key color management experts:

Their expertise played a critical role in ensuring the proper integration, calibration, standardization, and optimization of the company’s color-managed print production workflow.

Training and Workflow Integration

Comprehensive color management training sessions were conducted for the company’s team, covering both basic and advanced usage of the installed software solutions. The training program ensured that all departments involved in the production workflow fully understood the implementation, operation, and maintenance of the color-managed printing environment.

The training focused mainly on:

• Proper operation of GMG software, PressSIGN solutions, and workflow tools.
• Understanding color standards and print consistency.
• Correct implementation of the company’s color-managed workflow.
• Team collaboration throughout sales, quality assurance, prepress, plate-making, and print production processes.
• Developing correct and appropriate color communication across departments and with clients.
• Building confidence in evaluating and approving color-critical outputs.

The involvement of the entire production and management team helped establish a more efficient, standardized, and quality-driven printing operation.

Expected Benefits

By implementing the proposed workflow solution, the client can expect:

• Improved print accuracy, consistency, quality, and repeatability.
• Reduced color variation and rework.
• Increased production efficiency.
• Better compliance with industry color standards.
• Enhanced customer satisfaction through reliable print quality.
• Time savings and less wastage.
• Increased profitability.
• Reduced dependence on highly skilled press operators.