Flexographic Colourist Course

Lesson 1 • Flexographic Press Components Overview

Introduces anilox rolls, plate cylinders, impression cylinders, and doctor blades. Establishes the mechanical context needed for all colour work.

Lesson 2 • Ink Systems in Flexography

Covers water-based, solvent-based, and UV-curable ink chemistries. Connects ink type to drying method and colour behaviour on press.

Lesson 3 • Substrates and Their Colour Impact

Examines how paper, film, foil, and corrugated surfaces absorb and reflect ink. Links substrate choice to colour outcome expectations.

Lesson 1 • Light, Vision, and Colour Perception

Explains how light sources, observer metamerism, and human vision create colour experience. Grounds all subsequent measurement and matching work.

Lesson 2 • Colour Difference and Tolerance

Covers Delta E formulas, perceptual uniformity, and industry tolerance standards. Enables students to judge pass/fail colour objectively.

Lesson 3 • Spectrophotometry and Densitometry

Teaches instrument operation, measurement geometry, and data interpretation. Connects instrument readings to real press colour decisions.

Lesson 4 • Ink Opacity, Transparency, and Tinting

Analyses how opacity and transparency affect layered colour builds. Prepares students to predict colour interactions before going to press.

Lesson 1 • Drawdown and Proof Evaluation

Demonstrates drawdown technique, proof comparison, and spectrophotometric evaluation. Bridges lab mixing to press-ready approval.

Lesson 2 • Viscosity Control and Adjustment

Teaches viscosity measurement with Zahn cups and digital viscometers and correction methods. Directly impacts ink transfer and colour density on press.

Lesson 3 • Pigment and Colorant Fundamentals

Identifies organic, inorganic, and special-effect pigments used in flexo inks. Links pigment selection to lightfastness, opacity, and cost.

Lesson 4 • Ink Mixing Systems and Formulas

Covers proprietary mixing systems, formula databases, and manual blending techniques. Establishes a structured workflow for consistent results.

Lesson 1 • Spot Colour Standards and References

Introduces industry spot colour systems, fan decks, and digital colour libraries. Establishes the reference tools colourists use daily.

Lesson 2 • Special Effect and Metallic Spot Colours

Addresses metallic, pearlescent, and fluorescent spot colour formulation and press challenges. Expands the colourist's capability beyond standard pigments.

Lesson 3 • Matching Spot Colours on Press

Covers ink laydown, anilox selection, and press condition variables affecting spot colour. Connects lab formulation to live press performance.

Lesson 1 • ICC Profiles and Colour Management

Covers ICC profile creation, application, and soft proofing for flexographic output. Links digital file preparation to predictable press colour.

Lesson 2 • Gray Balance and Neutral Reproduction

Teaches CMY gray balance targets and their role in overall colour accuracy. Neutral reproduction is the key indicator of a well-controlled press.

Lesson 3 • CMYK Ink Set Characterisation

Measures and profiles the actual CMYK ink set on a given press and substrate. Creates the data foundation for all process colour decisions.

Lesson 4 • Tone Reproduction and Dot Gain Control

Explains tone value increase curves, compensation strategies, and plate linearisation. Directly controls midtone accuracy and shadow detail.

Lesson 1 • Extended Gamut Printing Concepts

Defines extended gamut printing, its business drivers, and how it differs from CMYK. Positions the technology within modern flexographic production.

Lesson 2 • Ink Set Selection and Optimisation

Guides selection of additional primaries and their interaction with CMYK inks. Optimised ink sets maximise gamut while minimising ink costs.

Lesson 3 • Spot Colour Simulation in Extended Gamut

Teaches how to simulate brand spot colours using the extended ink set without dedicated spot inks. Evaluates simulation accuracy and acceptable tolerance.

Lesson 4 • Production Management for Extended Gamut

Addresses job setup, ink management, and press changeover for extended gamut production. Ensures operational efficiency alongside colour quality.

Lesson 1 • Makeready Colour Approval Process

Defines the structured approval workflow from first pull to signed-off makeready. Reduces waste and establishes a clear production baseline.

Lesson 2 • Colour Variation Root Cause Analysis

Provides a structured method for tracing colour variation to press, ink, plate, or substrate causes. Enables permanent corrective action rather than repeated adjustment.

Lesson 3 • Statistical Process Control for Colour

Applies SPC charts, Cpk analysis, and trend monitoring to colour data. Transforms reactive colour correction into proactive process management.

Lesson 4 • In-Line and Off-Line Measurement

Compares in-line spectrophotometric systems with off-line manual measurement workflows. Selects the right measurement approach for each production environment.

Lesson 1 • Colour Workflow Automation

Introduces automated colour conversion, preflight, and reporting tools that scale colour management. Automation reduces human error and speeds job turnaround.

Lesson 2 • Colour Management System Architecture

Designs an end-to-end colour management system from file receipt to press output. A well-architected system ensures predictability at every handoff.

Lesson 3 • Flexographic Colour Standards and Targets

Reviews industry printing condition standards and how to select and implement the right target. Standardisation reduces variability and simplifies customer communication.

Lesson 4 • Ink Cost Reduction Through Colour Optimisation

Applies under-colour removal, gray component replacement, and ink limit strategies to reduce ink consumption. Balances colour quality with measurable cost savings.