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Hexachrome

Hexachrome is a six-color printing process developed by Pantone in 1996, employing cyan, magenta, yellow, black, orange, and green inks—known as CMYKOG—to significantly expand the reproducible color gamut beyond the limitations of standard four-color CMYK printing.^[1] The system utilized custom-formulated process inks, with the orange and green components providing enhanced vibrancy for saturated hues, while the magenta and yellow inks incorporated semi-fluorescent properties to improve brightness but with reduced fade resistance in certain applications.^[2] Pantone supported the workflow with specialized software tools, such as the HexWare plugin for Adobe applications, enabling color separation, correction, and proofing tailored to the expanded ink set.^[3] Hexachrome aimed to simplify production by simulating approximately 90% of Pantone Matching System spot colors using process inks, thereby reducing the need for multiple spot color runs, minimizing ink inventory, and lowering wash-up times on presses.^[1] Its gamut exceeded industry standards like GRACoL 2006, allowing for more accurate reproduction of vivid graphics and photographs that were challenging in traditional CMYK.^[1] Despite initial promotion and testing in commercial printing, Hexachrome saw limited widespread adoption and was discontinued by Pantone around 2008, paving the way for subsequent expanded gamut technologies.^[1]

Fundamentals

Definition

Hexachrome is a proprietary six-color printing process developed by Pantone Inc. for commercial offset lithography and digital printing. This system builds upon traditional printing techniques by incorporating an expanded set of inks to enhance color reproduction capabilities. Pantone has held the trademark for Hexachrome since its inception, positioning it as a branded solution within the color management industry.^[4]^[5] The core distinction of Hexachrome lies in its departure from the standard CMYK four-color process, which relies on cyan, magenta, yellow, and black inks for subtractive color mixing.^[4] Hexachrome adds two additional process colors to the CMYK base, enabling a significantly broader color gamut that addresses limitations in the CMYK system's coverage of certain hues.^[5] In the subtractive color mixing paradigm of printing, where inks absorb light to produce visible colors on substrates like paper, Hexachrome is designed to reproduce a wider range of hues with greater fidelity.^[6] Specifically, it improves the rendering of vibrant oranges, greens, and flesh tones, which often appear muted or inaccurate in standard CMYK printing.^[5] This expansion allows for more vivid and realistic visual outputs in applications such as packaging, advertising, and publications.^[4]

Color Components

Hexachrome employs a six-color printing system utilizing the standard cyan (C), magenta (M), yellow (Y), and black (K) inks, augmented by orange (O) and green (G) inks, collectively abbreviated as CMYKOG. These inks operate on subtractive color mixing principles, where the additional colors extend the reproducible gamut by filling spectral gaps in the traditional CMYK set.^[7] The cyan, magenta, yellow, and black inks follow conventional process formulations optimized for high-fidelity reproduction, providing the foundational base for neutral tones and broad coverage. The orange ink is specifically formulated to enhance warm tones and reds, using a blend such as 20 parts PANTONE Fluorescent Orange 804 and 80 parts PANTONE Orange 021, which introduces higher saturation in the reddish-orange spectrum compared to standard CMYK mixtures. Similarly, the green ink improves reproduction of foliage and cool tones, formulated as 80 parts PANTONE Green and 20 parts PANTONE Yellow 012 to achieve vibrant mid-green hues that CMYK alone struggles to match without overprinting. All six inks adhere to Pantone's standardized formulations, ensuring consistency in density, viscosity, and spectral reflectance across compatible printing presses, with the chromatic inks exhibiting peak absorptions tailored to expand visible color ranges.^[7]^[8] In interaction with the CMYK base, the orange and green inks enable subtractive overprinting to simulate a wider array of hues, covering approximately 90% of Pantone Matching System spot colors without requiring custom mixing. This is achieved through the unique spectral properties of the added inks, which provide denser pigmentation in orange (around 600 nm wavelength) and green (around 550 nm) regions.^[9]^[7]^[8] The overall gamut expansion allows Hexachrome to encompass a significantly larger color space than standard CMYK, particularly in high-chroma areas like oranges, reds, and greens, enabling reproduction of colors that would otherwise fall outside printable limits. Quantitative assessments in CIE color space demonstrate this extension, with the Hexachrome volume exceeding CMYK by notable margins in targeted spectral bands, though exact multiples vary by substrate and press conditions.^[7]

History

Development

Hexachrome was developed by Pantone, Inc. in the early 1990s as an extension of its established spot color matching system, aimed at addressing the limitations of the standard CMYK process in accurately reproducing Pantone spot colors.^[10] The initiative was led by Richard Herbert, along with colleague Al DiBernardo, who are listed as the inventors on the core patent for the system.^[7] The primary motivation stemmed from growing industry needs for expanded color reproduction in commercial printing, particularly for vibrant hues used in advertising and packaging, without relying on costly additional spot ink runs that CMYK could not achieve effectively.^[7] This demand highlighted CMYK's restricted gamut, especially for bright oranges, greens, and certain blues common in Pantone's color library.^[7] Pantone's research phase involved extensive testing to identify ink additions that would broaden the color spectrum while remaining compatible with existing offset printing equipment. Spectral characteristics of various pigments were analyzed to determine optimal expansions, leading to the selection of orange and green as the supplementary colors based on their ability to fill gaps in the reproduction of prevalent commercial shades.^[7] Development progressed through internal prototyping in the mid-1990s, with a focus on algorithms for gamut mapping to enable seamless separation of images into six channels: cyan, magenta, yellow, black, orange, and green. This culminated in the filing of U.S. Patent No. 5,734,800 on November 29, 1994, which detailed the ink formulations and process for achieving over 90% matching of Pantone spot colors using process printing.^[7]

Introduction and Adoption

Hexachrome, a six-color printing process developed by Pantone, was officially launched in May 1995 at the DRUPA trade show in Germany. Pantone promoted it as a revolutionary system for expanded gamut printing, incorporating orange and green inks alongside cyan, magenta, yellow, and black to reproduce approximately 90 percent of Pantone spot colors using process inks alone. Early partnerships accelerated its integration into industry workflows. Pantone collaborated with software developers including Adobe and Quark to enable Hexachrome support in design applications. Concurrently, licensing agreements were established with printer manufacturers such as Hewlett-Packard, Lexmark, and Xerox for hardware certification and compatibility. The initial adoption focused on high-end commercial printing, particularly for catalogs, magazines, and packaging where enhanced color vibrancy and accuracy were essential. Pantone supported this uptake through marketing materials, including the publication of the Hexachrome Color Guide, which provided swatches and separation guidelines for practitioners.

Discontinuation

Hexachrome was discontinued by Pantone in 2008, primarily due to Adobe Systems' decision to withdraw support for the HexWare plugin in Photoshop CS4 and subsequent versions, which had been essential for color separations and workflow integration since the system's launch in the 1990s.^[11] Several contributing factors accelerated this decline, including the rising popularity of digital printing technologies that offered more flexible alternatives to offset processes, reducing the need for specialized six-color setups. Additionally, the high costs associated with maintaining and operating six-color presses—estimated at about 50% more than standard four-color equipment—proved prohibitive, especially amid the 2008 global economic downturn that strained printing industry budgets.^[11]^[12] In the immediate aftermath, Pantone halted production of Hexachrome-specific color guides and inks by 2009, effectively ending official support for the system. Remaining certified printers largely reverted to traditional CMYK workflows or transitioned to emerging expanded gamut printing methods, such as those incorporating orange, green, and blue alongside CMYK.^[11]

Technical Implementation

Software Requirements

The core software for preparing files for Hexachrome printing was the Pantone-developed HexWare plugin suite, which included HexImage for raster image processing in Adobe Photoshop versions 4.0 through CS3, enabling six-color separations from RGB or CMYK sources and advanced gamut mapping to incorporate orange and green inks alongside the standard CMYK components.^[3]^[13] HexWare facilitated precise color conversion by leveraging Pantone's proprietary ICC profiles, which were installed with the plugin to ensure accurate on-screen previewing of the expanded Hexachrome gamut.^[14] Integration with layout applications was supported natively in QuarkXPress starting from version 4.0, allowing direct handling of Hexachrome color spaces and ICC profiles for page assembly without additional plugins. Early versions of Adobe InDesign, up to CS3, provided ICC profile compatibility for importing and managing Hexachrome-separated files, though full separation required the HexWare plugin in Photoshop.^[15] For final press output, custom Raster Image Processor (RIP) software such as EFI Fiery was essential, as it processed the six-channel separations (CMYKOG) using embedded Pantone ICC profiles to generate plates for Hexachrome presses.^[16] The typical workflow began with image preparation in Photoshop using HexWare: designers imported RGB or CMYK files, applied the Hexachrome ICC profile for soft proofing, and executed separations via the plugin's tools to output DCS 2.0 or multi-channel EPS files with dedicated orange (O) and green (G) channels.^[3] These files were then placed into QuarkXPress or InDesign for layout, exported as PDFs with preserved profiles, and sent to the Fiery RIP for halftoning and plating, ensuring color fidelity throughout pre-press. Pantone supplied standardized ICC profiles for various press conditions, such as coated and uncoated stocks, to maintain consistency in gamut expansion and out-of-gamut clipping.^[14] Post-2008, HexWare lost official support following Adobe's discontinuation of compatibility in newer Photoshop versions (CS4 and later), rendering the plugin unusable in modern Adobe Creative Suite workflows and limiting Hexachrome file handling to legacy software installations.^[13] For legacy files, users could resort to custom scripts in older Photoshop editions or third-party converters to simulate separations, though these lacked the precision of original HexWare tools and required manual ICC profile management.^[17] Current Adobe applications convert Hexachrome elements to standard RGB or CMYK upon import, necessitating archival hardware for authentic reproduction.^[15]

Printing Process

The pre-press phase of Hexachrome printing begins with the separation of digital files into six color channels—cyan (C), magenta (M), yellow (Y), orange (O), green (G), and black (K)—utilizing specialized software tools designed for multichannel processing, such as HexWrench or plugins integrated with Adobe Photoshop.^[18] Once separated, printing plates for each ink are produced, commonly via computer-to-plate (CTP) systems to achieve high-fidelity imaging and alignment across the expanded color set.^[18] On the press, Hexachrome employs modified offset lithographic equipment featuring six dedicated ink fountains to handle the additional orange and green inks alongside standard CMYK.^[18] The inks are applied sequentially in an order that positions complementary colors apart to reduce misregistration effects and improve overlay precision during the multi-unit run, such as yellow, orange, magenta, green, cyan, black.^[18] Each color layer is rendered through halftone dot patterns at line screen resolutions of 150-175 lines per inch (lpi), enabling smooth tonal gradients while the total ink density is capped at approximately 300% to prevent excessive buildup and facilitate proper drying on the substrate.^[18]^[19] Quality control during Hexachrome production relies on calibration with dedicated Pantone Hexachrome test forms, which include standardized color patches and gradients to verify gamut expansion, density targets, and consistency across print runs.^[18] These forms are printed and measured to adjust press settings, ensuring accurate reproduction of the expanded color space from pre-press separations through final output.^[18]

Advantages and Disadvantages

Benefits

Hexachrome expands the color gamut beyond traditional CMYK printing by incorporating orange and green inks, enabling the reproduction of approximately 90% of Pantone spot colors using process inks alone.^[20]^[21] This capability significantly reduces reliance on expensive spot color applications, particularly for vibrant oranges and greens that are challenging in standard four-color processes.^[6] The system offers cost efficiencies by minimizing ink wash-downs and setup changes between jobs, as the six inks remain loaded on certified presses for multiple runs.^[22] This streamlines production for short runs in packaging and advertising, lowering overall setup time and operational expenses compared to frequent color changes in CMYK workflows.^[23] Hexachrome provides enhanced color reproduction fidelity, particularly for skin tones, pastels, and natural elements, resulting in more realistic and vibrant renditions than achievable with CMYK.^[24] Industry evaluations have demonstrated its superiority in capturing nuanced hues, such as brighter skin tones and smoother gradients in organic imagery.^[25] By decreasing the need for additional spot color passes and overprints, Hexachrome supports potential reductions in ink waste relative to multiple CMYK production cycles.^[26]

Limitations

One major limitation of Hexachrome was the high setup costs associated with implementing the system, as it required modifications to existing printing presses to add two additional printing units for the orange and green inks. Additionally, the specialized ink formulations contributed to higher ongoing expenses compared to standard CMYK. Compatibility issues further hindered adoption, as Hexachrome relied heavily on proprietary software such as Pantone's HexWare plugin, which became obsolete after Adobe discontinued support in 2008, rendering the system incompatible with modern workflows without custom engineering.^[27] Not all digital presses could support six colors natively, often necessitating expensive retrofits or new equipment. The learning curve for operators was steep, requiring retraining in color separations, ink mixing, and quality control processes, due to the increased complexity of managing six inks.^[28] Market constraints also limited Hexachrome's viability, as it proved less effective for black-and-white dominant jobs where the expanded gamut offered minimal benefits, and the advantages were marginal for standard office printing applications focused on grayscale reproduction.^[28]

Adoption and Legacy

Key Users

Major software developers integrated support for Hexachrome into their design tools to facilitate the expanded color gamut. Adobe Systems incorporated Pantone's HexWare plugin suite, including HexImage for Photoshop and HexVector for Illustrator, enabling designers to separate images and vectors into the six-color process directly within these applications.^[3] Quark Inc. added Hexachrome compatibility to QuarkXPress, allowing users to output files optimized for the CMYKOG ink set in desktop publishing workflows. Similarly, Adobe PageMaker 6.5 included built-in support for Hexachrome separations, marking early compatibility for layout software.^[29] Hardware manufacturers certified several printers for Hexachrome output, particularly in the late 1990s, to meet the demands of high-fidelity color reproduction. HP's Indigo digital presses were among the first to support the process, with models like the Indigo 3000 enabling on-demand Hexachrome printing through liquid electrophotography; Pantone later sold the technology to HP, evolving it into the IndiChrome system that utilized orange and violet inks for even broader gamut coverage.^[10]^[30] Commercial printers adopted Hexachrome for applications requiring vibrant, spot-color-like results in catalogs and packaging. For instance, Visual Systems Inc. integrated the process into its color management workflow in 2002, using it to produce photorealistic prints with reduced spot color overprints on offset and digital equipment.^[5] Creative agencies utilized Hexachrome for advertising materials where precise color matching enhanced brand visuals. By the mid-2000s, a few hundred printers worldwide were using Hexachrome, reflecting limited but notable implementation among those focused on premium collateral.^[31]

Impact and Successors

Hexachrome pioneered expanded gamut color (EGC) printing by introducing a six-color process (CMYK plus orange and green inks) in 1996, enabling printers to reproduce approximately 90% of the Pantone spot color library without additional plates.^[1] This innovation expanded the reproducible color range beyond traditional CMYK limitations, laying the groundwork for multi-primary printing systems that prioritize efficiency and spot color simulation.^[32] Its development influenced industry standards by demonstrating the feasibility of EGC, which exceeds the color gamuts defined in ISO 12647-2 for standard print conditions like GRACoL, and contributed to later specifications such as ISO/TS 21328:2022 for characterizing CMYKOGV processes.^[1]^[32] The system also played a key role in Pantone's transition toward comprehensive digital color libraries, as Hexachrome integrated over 2,000 Pantone colors into digital workflows for coated and uncoated stocks, highlighting the need for accessible, process-specific color data in software like Adobe applications.^[18] By embedding Pantone's color matching directly into printing pipelines, it accelerated the shift from physical swatch books to digital platforms like Pantone Connect, which now provide equivalents in RGB, CMYK, and other spaces across all libraries.^[33] In the broader industry, Hexachrome popularized the use of orange and green as supplementary inks in CMYK+ configurations, enhancing chroma for vivid oranges, greens, and flesh tones that were challenging in four-color processes.^[20] This approach has been cited in printing research as a foundational precursor to seven-color experiments, where violet is added to CMYKOG for even broader gamut coverage, achieving up to 90% Pantone matching in applications like flexible packaging.^[32]^[20] Modern successors to Hexachrome include advanced EGC systems such as Pantone's 2015 Extended Gamut Coated Guide, which employs CMYKOGV to simulate spot colors with reduced waste, and workflows supported by tools like GMG ColorProof for proofing extended gamuts with spot color integration.^[32]^[34]^[35] ONYX RIP software facilitates seven-color production in wide-format printing, enabling consistent color management for multi-ink setups that build on Hexachrome's principles.^[36] Digital alternatives encompass Adobe's historical support for multi-channel separations and spot color emulation in PDF/X-4 standards, which allow device-independent color spaces to approximate expanded gamuts without proprietary hardware.^[37]^[38] Today, Hexachrome maintains relevance in archival contexts for processing legacy files from its era and sees occasional revival in niche high-end printing, such as custom label production, where printers configure CMYKOG setups for superior color fidelity despite its discontinuation in 2008.^[20]^[32]

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