How Color Matching Works in Custom Plastic Extrusion

In custom plastic extrusion, color isn’t just about aesthetics–it’s often a critical part of branding, functionality, or compliance. Whether a customer needs a medical tube that matches a standard color code, a branded profile that aligns with company colors, or a protective cover with UV-stable pigmentation, precision color matching ensures consistency across every part produced. 

At Inplex, achieving accurate, repeatable color requires a blend of science, technology, and experience.

The Importance of Color Consistency

Color consistency is essential for product recognition and quality assurance. In applications like consumer products or medical devices, even small variations in hue can be unacceptable. For industrial components, consistent coloration can help identify part types or meet specific safety and regulatory standards. 

Maintaining that consistency throughout long production runs is one of the defining capabilities of an experienced extrusion partner.

How the Color Matching Process Begins

Color matching typically starts with a target sample or specification provided by the customer. This could be a physical part, a color chip, or a reference from a recognized color system such as Pantone or RAL. Inplex’s team then works with resin suppliers and color specialists to develop a custom formulation that meets the desired shade while maintaining the required material performance.

Each formulation considers not just the colorants, but also the base resin, additives, and processing conditions. Because different plastics, such as PVC, polyethylene, or polyurethane, respond differently to pigments, the same color formula can look slightly different depending on the polymer. The goal is to achieve the target color while ensuring the extrusion still meets mechanical, thermal, and regulatory specifications.

Precision Through Testing and Adjustment

Once an initial formulation is created, small-batch samples are extruded for evaluation. These samples are compared to the reference under controlled lighting conditions to assess accuracy. Subtle adjustments in pigment concentration or type may be made to fine-tune the match.

Inplex uses advanced color measurement tools such as spectrophotometers to ensure objective, repeatable readings of color values. This scientific approach allows technicians to quantify how close a sample is to the desired shade, rather than relying solely on visual inspection.

Maintaining Color Accuracy in Production

Once a color match is approved, Inplex documents the exact material blend, extrusion temperature, and other key parameters to ensure that future runs maintain the same appearance. During production, technicians continuously monitor both visual and instrument-based color consistency, making small adjustments if needed to compensate for batch variations or environmental factors.

For products requiring long-term stability, especially those exposed to UV light, heat, or chemicals, Inplex can incorporate stabilizers and performance additives to help the color stay true over time.

Turning Color Into Capability

Color matching in plastic extrusion is both an art and a science. It demands an understanding of polymers, pigments, and process control, as well as a commitment to repeatable quality. Through close collaboration with customers and material suppliers, Inplex ensures that every custom extrusion delivers not only the right performance, but also the right color, every time.

Custom Extrusion with Inplex

Looking for quality custom extrusion products and services? Inplex is one of the leading custom extrusion services in the US and has almost 60 years of experience. We pride ourselves on our ability to put the right talent and technology in place to perform the best possible job for our clients.

We own a 42,000 sq. ft. facility in Naperville, Illinois, that is temperature-controlled and features an environmentally friendly closed-loop water cooling system. If you have specific needs or questions, don’t hesitate to contact us!