Apex International, a global manufacturer of quality anilox rolls and sleeves, has closely monitored the advantages and complexities of expanded color gamut, or fixed color palette, printing since its inception. Over the past decade, we have innovated anilox solutions to maximize the performance of ECG printing and make the transition to this application as seamless as possible. Though it is no easy feat, there are a number of undeniable benefits to extended color gamut printing which we will discuss in this article.
Getting Started with ECG Printing
Expanded color gamut (ECG) printing has been a possibility within the Flexographic industry for over 20 years. However, many converters have yet to achieve the uptime, run consistency and savings associated with this printing process.
By now, you have most likely attempted the ECG printing process at least once, only to find you were unable to control the precise ink laydown required for accurate Pantone color builds. What began as an initiative to cut costs and increase production, ended up with the complete opposite outcome: more waste and downtime. To truly achieve the benefits of this process, you must get serious about anilox standardization and process control.
#1. Efficiency. Efficiency. EFFICIENCY!
The #1 reason printers attempt ECG printing is for the incredible efficiency it can bring to your press operations. With color gamut printing both the ink and the anilox can remain the same from print job to print job: cyan, magenta, yellow and black, plus orange, green and/or reflex blue or violet for extended color gamut. Apex has witnessed ECG printers dramatically reduce downtime associated with ink and anilox changeovers, wash ups, and cleanings (up to 90%). Printers previously operating at about 40% production time can optimize to over 70% production time by implementing CG and ECG printing practices.
#2. Color Vibrance, Realism & Consistency
Using a 7-color process, printers can print up to 90% of Pantone colors with ease (around 45% for 4-color processes). ECG is also known for its consistency and precise representation of color, due to less variability in the printing process. With a wider range of available colors, ECG prints exhibit the more vibrant, bold, and rich colors that brands expect. Shadows and subtle details appear more lifelike in ECG printing than traditional 4-color prints making it perfect for the luxury beauty and cosmetics packaging industries.
#3. Bottom Line Savings
The alternative to ECG is spot color printing which utilizes pre-mixed spot color inks to achieve the standard brand colors required in each print job. However, there is always leftover ink after the job is finished. Due to the amount of ink needed to circulate through the pipes and doctor blade chamber, these left over spot colors will be put in press return stock for remixing or get discarded, sending valuable raw materials down the drain. By utilizing a standard 4- or 7-color ink process, printers no longer need to create unique spot colors for each print run. Facilities can virtually eliminate ink waste from their facility and optimize their ink inventory for performance, rather than by color availability.
Using the Veritas inspection system, available through Apex International, Printers can evaluate, track, and maintain their anilox inventory for the best performing aniloxes for ECG printing. Ask our team about this FTA-award winning innovation today.
#4. In-Line Specialty Effects
The extra print stations available when printing 4C compared to ECG enable printers to not only print extra spot colors if desired, but they can also be used to print specialty adhesives and coatings for foil printing and special effects. Effects, such as tactile coatings, soft touch coatings, raised spot gloss, foil embellishments and more, can be printed in-line using the extra print stations for those luxury print clients. With the added efficiency, savings and short run benefits of 4C/ECG, flexo printers can remain competitive and adaptive as they diversify their product portfolio and customer base.
#5 Shorter Runs & Digital Competition
By optimizing ink and anilox volumes for minimal changeovers, 4C/ECG printers can produce shorter runs profitably and compete with digital short run formats. Capable of higher quality print, in-line specialty effects and increased savings, expanded color gamut printing allows converters the opportunity to competitively bid for more short run jobs in new and upcoming markets. By diversifying their customers and working with 
premium luxury brands from inception, printers can expand their sales with 4C/ECG capabilities.
Expanded color gamut (ECG) printing has been a possibility within the Flexographic industry for over 20 years. However, many converters have yet to achieve the uptime, run consistency and savings associated with this printing process.
Discover actionable steps to getting started with ECG in this article from Apex International “Unlocking Extended Color Gamut Profitability with Anilox Quality Control”, originally published in FLEXO magazine in June 2023.
Apex International is an expert in anilox roll solutions that help streamline your transition to ECG printing efficiency. Contact our team today to discuss your ECG initiative and get started with an Apex consultation.
