Hitting offset lithographic color targets isn’t always fast or easy. The manual process of measuring color bars and making ink key adjustments takes time and opens the door to operator error. Meanwhile, the press is running (and wasting) paper and ink. To achieve accurate and repeatable color, printers need to convert their printing operation to an efficient manufacturing process and drive efficiencies in all phases of their operation. For many, a closed-loop automated solution is the answer.
Closed-loop automates the process by capturing spectral data directly from the press sheet and automatically updating the ink keys. It cuts down on paper and ink expenses that accumulate when you’re not getting up to color quickly, makes short runs more profitable, and minimizes operator intervention. It’s so much faster and more accurate than a traditional workflow that it pays for itself almost immediately.
Is your printing operation ready for a closed-loop solution? Today we’re looking at the tools and software you need to upgrade.
Color Measurement Tools to Automate Press Sheet Scanning
Capturing spectral data is the first step in automating your workflow, and we offer two devices that integrate seamlessly with closed-loop control. While both can be used on their own, they gain more power as part of a complete solution.
IntelliTrax2 Automated Scanning System
The IntelliTrax2 automatically scans the color bar of a typical press sheet in less than 10 seconds, then provides instant, on-screen reports. The advanced imaging technology in IntelliTrax2 automatically adjusts the scanning head to locate the color bar, ensuring faster sheet positioning and accurate measurements every time. Since it's non-contact, you don't need to worry about smudging or scratching the image.
eXact Auto-Scan Versatile Scanning Solution
The eXact Auto-Scan offers press room flexibility for measuring color with spot, manual, and automated scanning capabilities. When scanning, the eXact Auto-Scan can measure a 40-inch color bar in less than 15 seconds, reducing the potential for human error and cutting make-ready by more than 30%. It reports immediate, comprehensive color data through Bluetooth technology so press operators can make prompt adjustments to the press run.
Software to Automate Ink Key Adjustments
X-Rite IntelliKey software connects with IntelliTrax2 and eXact Auto-Scan to automate ink key presetting and closed-loop adjustments. Through an intuitive touchscreen interface, operators can select jobs, review measurement data, and initiate or reject adjustments while printing to G7, ISO, or in-house standards.
The solution is available in two configurations:
IntelliKey Plus for Advanced Pressroom Automation
Designed for packaging and high-volume environments (up to 20 units web or sheetfed presses of any width), IntelliKey Plus combines ink key presetting with closed-loop color control across multiple web and sheetfed presses. Before production begins, the software uses CIP or TIFF data from prepress to calculate initial ink key settings. Operators simply select the job and paper type to prepare the press for makeready.
During production, measurement data from periodic press-sheet scans guides automatic ink key adjustments. The software alerts operators when corrections are needed, helping maintain consistent color throughout the run. IntelliKey Plus also supports advanced capabilities such as automated CIP3 file processing, stack-light signaling, and color bars printed on white backing.
IntelliKey for Essential Closed-Loop Control
IntelliKey provides a streamlined option for commercial printers that want to add automated ink key control without the advanced capabilities included with IntelliKey Plus. Compatible with IntelliTrax2 and eXact Auto-Scan, it offers closed-loop functionality, but does not include higher tier components like Pre OPS automation for automated CIP3 files processing, stack light signaling, or support color bars on printed white backing.
Is a closed-loop system worth the investment?
A closed loop system doesn’t just pay for itself, it transforms how your pressroom operates. By standardizing color, reducing waste, and giving operators clearer control, you can consistently deliver higher quality work with less effort.
If you’re ready to explore what this could look like in your environment, use our Closed Loop ROI Tool to calculate your potential savings.
Contact our Color Experts today to learn how to enhance the performance of your press.
