The Challenge

• Reproducing accurate proofs for flexo converters and brand owners
• Creating proofs on proofing media and final production substrates
• Converting customer data into press-specific color spaces
• Meeting high quality expectations from global brands
• Maintaining color consistency across multiple devices and applications

Key Results

• Production of 4-color and 7-color flexo proofs
• Implementation of fixed CMYK + OGV workflows
• Use of X Gamut for press-specific color conversion
• Alignment of large-format output with ISOcoated v2
• Use of Certified for spot color and 7-color validation

Accurate Proofing for Flexo and Brand Approval

In flexo production, reliable proofing is critical. HL Repro uses CGS ORIS Flex Pack to create both flat proofs and realistic mock-ups for converters and brand owners.

The Workflow Combines Two Approaches

• Conventional proofs on Epson printers using CGS ORIS Pearl PROOF media
• Substrate-based proofs produced via heat transfer onto the final material using
• Roland VSi printers and the CGS ORIS
• XG INK set (CMYK plus Orange and Green)

This allows HL Repro to simulate final print results under real production conditions. Both 4-color and 7-color proofs can be produced with a high level of accuracy, giving customers confidence before going to press.

Extended Color Gamut in Production

To improve efficiency in flexo printing, HL Repro relies on X Gamut.
The system allows n-color separations based on a fixed ink set consisting of CMYK plus Orange, Green and Violet.
This approach reduces the need for frequent spot color changes on press.

X Gamut also functions as a color server. It converts incoming customer data, for example ISOcoated v2, into the exact measured color space of each press.

A key advantage is the 4-dimensional conversion technology, which preserves the black channel. This leads to more stable results compared to conventional CMYK to Lab to CMYK conversions.

The Result

• Less setup time
• Reduced material waste
• More stable production conditions

Consistent Results In Large-Format Printing

HL Repro applies the same color logic in its large-format production.
Within the HL Print division, X Gamut is used in combination with the principles of Press Matcher to align output with industry standards such as ISOcoated v2.
This is particularly important for international clients with strict brand requirements. One example is a global textile retailer with more than 1,000 stores, where display materials must match across all locations.

Quality Control and Certification

To maintain consistent output, HL Repro uses CGS ORIS Certified for process control and validation.
The system supports print certification across devices and substrates, spot color validation and full 7-color certification workflows. This ensures that production results remain consistent across different print runs and locations.