Thanks for the reply.
The processes we are using can vary so much that it’s extremely hard to nail it down to a consistent standard.
The chemistry:
Although we mix / formulate our own cmyk inks from base pigments. Along with film production this is probably the most consistent part of the operation.
The screens;
This is the most variable part of the operation due to a multitude of reasons too many to list. It is however controlled as is practically possible.
The Material:
We always print on the same cloth. Although the white point of the cloth varies from batch to batch as dose the construction / absorbency, it falls within industry tolerances. These tolerances are far, far wider than any spec for paper would ever be.
Press
A press operator can expect to adjust a press for at least the first twenty minuets before it will stabilise as well as make adjustments during a print run. Lots of variables here that an experienced press operator can use to good advantage.
Targets and Instruments
We have had profiles made for us out of house (remote service) using the IT8.7-3 and i1 ECI targets. In house we use an SP68 (designed for reading textiles) print large targets (up to 18” x 36”) and measure the patches by hand - average of 10 readings per patch. Even how many threads there actually are per inch in the cloth where the patch is printed / measured is a variable and effects the light reflected from the sub straight under the cloth (I use a neutral grey)
With all the variables the only reason I think we can ever acheive any acceptable cmyk print is because our reproducible gamut, by flexo standards, is very limited, ie the fewer colours there are to reproduce the easier it is to reproduce them.
After 12 years of trying to nail a standard I’m beginning to think it is somewhat futile, the only reason for continuing the quest is of course professional pride - we can always do better. However when jobs fail even after remaking screens etc. I suspect it has more to do with image type, black generation and the black generation settings locked in the custom profile we are using.
My reasoning for using Photoshop was two fold, one to try and absorb all the variables. There are only 8 patches + a white to read. (A ‘phone enquiry to X-rite a number of years ago lead me to believe that fewer patches may, for us, produce better results). The second reason was for altering / experimenting with the black generation based on the image being prepared for print, ie is it dark or light, high contrast / low contrast etc.
So, to conclude do you still think I’m heading down the wrong road with Photoshop? Would a ColourMunki be better?
Other than give up, (which for me isn’t an option!) any other advice?
Thanks for you time.
Jon