Digitalisation across the globe: Produce locally, colour match globally

Regionalising production has become an increasingly attractive strategy for coatings manufacturers seeking greater resilience. Producing closer to customers reduces dependence on long-distance supply chains, shortens lead times and enables companies to respond more quickly to regional demand or raw material shortages. However, manufacturing the same product across multiple facilities introduces a new challenge: maintaining identical colour regardless of where production takes place.

As companies expand regional manufacturing networks, colour consistency becomes a business continuity issue rather than simply a laboratory concern. Success depends on reliable measurement, shared data, standardised workflows and connected digital systems that allow every site to work from the same colour standards.

Regional production increases colour complexity

Producing identical coatings at multiple locations is rarely straightforward. Although colour formulas may be shared globally, production conditions often differ considerably between sites.

Differences in pigment batches, suppliers, base materials, environmental conditions, weighing accuracy, application methods, curing conditions and substrates can all influence the final appearance. Industrial coatings introduce additional variables such as baking cycles and gloss levels, while architectural coatings require frequent reformulation as new collections and regulations emerge.

Each additional manufacturing site increases the number of variables that laboratories and production teams must control. As production becomes more distributed, maintaining colour consistency becomes increasingly dependent on disciplined processes rather than individual expertise.

Digital colour only works when measurements agree

Digital colour management allows laboratories to exchange reflectance data instead of relying on physical standards. A colour measured in Europe can immediately be shared with colleagues in North America or Asia, allowing faster formulation and production.

This approach is only effective, however, when every instrument produces comparable measurements. Inter-instrument agreement forms the foundation of global colour management. Instruments that drift or are poorly maintained may still generate highly precise data, but those measurements are no longer reliable if they are based on different reference conditions.

For that reason, companies benefit from standardising spectrophotometers across facilities while maintaining consistent calibration, verification and maintenance procedures.

Shared systems support global production

Digital colour management extends well beyond measurement devices. Manufacturers also need common software platforms, shared colour databases and connected workflows that allow formulations, standards and production data to move seamlessly between facilities.

When every location accesses the same approved formulas and digital standards, production can be transferred between sites with far greater confidence. Integration with ERP and production systems enables approved formulations to move rapidly from laboratory to manufacturing, while central databases eliminate duplicated formulation work.

Shared systems also provide valuable operational visibility. Manufacturers can compare correction rates, monitor instrument status, identify training needs and recognise recurring process issues across multiple facilities.

The growing pace of reformulation—driven by changing regulations, raw material availability and new product introductions—places increasing pressure on coatings laboratories.

Digital colour management helps address four priorities simultaneously.

Better first-pass formulations reduce correction cycles, minimise rejected batches and lower raw material consumption. Shared databases prevent multiple laboratories from repeating identical work, reducing overall development costs.

Automation accelerates colour development by streamlining measurement, recipe calculation and formulation. Robotic laboratories can also reduce sample sizes dramatically, cutting both material use and development time.

Customers continue to expect identical colour regardless of where products are manufactured. Meeting these expectations depends on repeatable measurement, well-maintained instruments and consistent digital standards across every production site.

Sustainability also benefits. Fewer trial batches, fewer corrections and less wasted material reduce both costs and environmental impact, particularly as manufacturers reformulate products to meet lower-VOC requirements or adopt alternative raw materials.

Standardisation becomes increasingly important

Regional production inevitably increases the likelihood of variation. Local suppliers, substitute pigments and changing production conditions often require formulation adjustments even when the target colour remains unchanged.

For this reason, colour governance becomes increasingly important as manufacturing networks become more flexible. Consistent measurement procedures, controlled environmental conditions and regular instrument maintenance ensure that digital colour standards remain reliable over time.

Temperature is frequently overlooked despite its significant influence on measurement results. Even relatively small temperature differences can affect the measured values of certain colours, making controlled measurement environments an important part of global colour consistency.

Automation and AI complement expertise

Automation is becoming an increasingly valuable tool for handling routine formulation work. Automated measurement, recipe generation and correction workflows allow laboratories to process larger numbers of colours while reducing repetitive manual tasks.

Inline and near-line measurement also offer opportunities to detect colour deviations earlier during production, reducing waste and shortening correction cycles. These technologies, however, require careful consideration of drying, curing and other process variables.

Artificial intelligence is likely to become a valuable assistant rather than a replacement for colour science. AI can help users navigate complex software, support training and identify recurring formulation or instrument trends from historical data. Predictive maintenance and process optimisation represent promising applications.

Nevertheless, successful AI still depends on reliable measurement data, disciplined workflows and experienced technical judgement. High-quality data remains the foundation of every digital colour management system.

Outlook

Regional manufacturing gives coatings producers greater flexibility and resilience, but only when every production site works from the same trusted colour standards. Standardised instruments, connected software, shared databases and disciplined measurement practices enable manufacturers to produce locally while delivering globally consistent colour.

As production networks become more distributed, digital colour management is evolving from a laboratory tool into a strategic capability that supports efficiency, quality and long-term business resilience.

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