Matching is the starting point
An approved shade must also be reproduced on the actual production equipment. Matching results alone cannot establish consistency across two application technologies.
NUMIX · AUTOMOTIVE REFINISHING
Automotive Tinting Guide System | Color Chart & Fan Deck
1K & 2K color systems manufactured for international distribution
AUTOMOTIVE REFINISHING · MANUFACTURING CASE STUDY
Two Paint Systems. Four Formats. Multiple Markets.
For a UAE-based automotive refinishing customer, PHOENiX Sample manufactured 1K and 2K color charts and fan decks in several-thousand-unit runs per format, with shipments distributed across multiple countries.
- Featured brand
- NUMIX / National Paints branding
- Client / distribution
- UAE-based client · shipments to multiple countries
- Deliverables
- 1K & 2K color charts and fan decks
- Project status
- Completed manufacturing project
301 Color entries across both systems
4 Manufactured product categories
97% Approved in the first matching round
Thousands Units per product category
Project Overview
1K BASE COAT · 205 COLOR ENTRIES
A Coordinated 1K & 2K Color Reference Program
PHOENiX Sample developed a coordinated automotive tinting guide for a customer based in the United Arab Emirates. The program covered 1K base coat and 2K top coat systems, each supplied as both a color chart and a fan deck.
Several thousand units were manufactured in each of the four formats. Completed products were shipped in different quantities to multiple countries, extending the project beyond a single local market.
The central requirement was consistency: a shade approved against the customer’s reference had to communicate the same appearance in a large-format chart and a fan deck, despite different application equipment.
The Technical Challenge
2K TOP COAT · 96 COLOR ENTRIES
One Approved Appearance Across Two Application Processes
Color charts were produced from large sheets using robotic spray application, while fan deck components were sprayed on a dedicated fan deck machine. Both processes had to reproduce the same approved color references.
This transfer was especially sensitive for metallic and other effect finishes. Flake orientation, film build and viewing angle can influence the final appearance even when a shade uses the same reference formulation.
Quantified Color Program
301 Color Entries in Two Paint Systems
The 1K system included 127 solid, 24 metallic, 40 pearl and 14 Xirallic entries. The 2K system included 88 solid and 8 metallic entries. The graph shows the documented finish mix, not the number of units manufactured.
- Solid
- Metallic
- Pearl
- Xirallic
| Paint system | Solid | Metallic | Pearl | Xirallic | Total |
|---|---|---|---|---|---|
| 1K | 127 | 24 | 40 | 14 | 205 |
| 2K | 88 | 8 | — | — | 96 |
| Total | 215 | 32 | 40 | 14 | 301 |
301 is the sum of the 1K (205) and 2K (96) program entries. The source does not establish whether any shade names overlap between the two systems. An em dash means that the finish was not listed for that system.
Matching & Approval
97% Approved in the First Matching Round
After matching the customer’s color standards, 97% of shades were approved in the first submission. The remaining 3% were adjusted and accepted in the second round.
97% Approved · first round
3% Approved · second round
All colors approved after two matching rounds
Percentages are the reported project-level figures; exact counts of approved shades per round were not supplied.
Effect Color Control
METALLIC APPEARANCE · DUAL-PROCESS CONTROL
Metallic Effects: Why Application Conditions Matter
Automotive metallic shades depend on how aluminum flakes distribute and orient within the coating. Small changes in spraying conditions can alter face color, flop, brightness and perceived texture—even between shades with similar appearances.
The project therefore required close comparison between robotic chart spraying and fan deck spraying. Pearl and Xirallic shades introduced further angle-dependent effects and needed the same attention to application consistency.
Manufacturing Method
From Customer Standards to Delivered Tinting Guides
- 01
Reference evaluation
Receive and classify the customer’s approved shades as solid, metallic, pearl or Xirallic.
- 02
Color matching
Match the supplied standards and submit the first round for customer approval.
- 03
Pilot verification
Check appearance after transfer from matching to the actual production machines.
- 04
Dual-process application
Use robotic spraying for color charts and the dedicated fan deck spraying machine for fan deck samples.
- 05
Cross-process quality control
Monitor visual consistency, coating uniformity and effect appearance across both formats and production batches.
- 06
Assembly & final delivery
Complete assembly, inspect the finished products and deliver each of the four ordered formats.
FINISH MIX COMPARISON
Solid and Effect Finishes by System
A proportional view of the color entries: 1K combines solid, metallic, pearl and Xirallic shades; 2K includes solid and metallic shades.
1K Base Coat 205
127 · 62.0%78 · 38.0%
2K Top Coat 96
88 · 91.7%8 · 8.3%
Effect colors include metallic, pearl and Xirallic in 1K; the 2K effect group contains metallic colors only.
Quality Assurance
Quality Control Across Formats and Production Runs
The approved physical standards remained the reference during production. Quality checks focused on color and effect appearance, coating uniformity, cross-process consistency, production repeatability and assembly.
The aim was a dependable visual reference for the end user, whether the color appeared on a chart or in a fan deck.
| Production stage | Quality-control focus |
|---|---|
| Reference evaluation | Classify supplied colors into solid, metallic, pearl and Xirallic finishes before matching. |
| Production transfer | Verify samples on the actual robotic chart line and dedicated fan deck spraying line. |
| In-process comparison | Compare appearance, coating uniformity, effect behavior and shade consistency across both formats. |
| Finished products | Check batch-to-batch appearance and assembly quality across the four product categories. |
Quality measures are described by production stage; no numerical color-tolerance value was supplied for publication.
Project Deliverables
Four Products, One Consistent Color System
The finished program covered all four combinations of paint system and presentation format, with several thousand units manufactured in each category.
01
1K Color Chart
Large-format color chart displaying 205 solid and effect color entries.
02
1K Fan Deck
Compact fan deck manufactured using the dedicated fan deck spraying line.
03
2K Color Chart
Large-format chart presenting 96 solid and metallic entries.
04
2K Fan Deck
Fan deck with a presentation box for the 2K color range.
Reported Results
Project Results
The figures below summarize the completed program as reported in the project brief.
97%
First-round color approval
100%
All colors approved by round two
4 formats
1K and 2K charts and fan decks
Two processes
Color-chart and fan-deck production aligned
Color counts are entries across the two systems; they are not necessarily distinct shades. Exact shipment volumes and destination countries have not been disclosed.
MANUFACTURING INSIGHTS
What This Project Demonstrates
Effect finishes require process control
Metallic, pearl and Xirallic appearance depends on application conditions and viewing angle, making visual comparisons between processes essential.
Repeatability matters at scale
Producing thousands of charts and fan decks requires consistent references and checks through coating, assembly and final inspection.
Related Expertise
Explore Relevant PHOENiX Capabilities
PROCESS FLOW DIAGRAM
Project Production Process
A clear view of the manufacturing stages used for this specific project.
Color development & approval
01
Color Standards Received
02
Color Matching
03
97% First-Round / 3% Second-Round Approval
Two dedicated production lines
Color-chart manufacturing
Color Chart Production — Robot Spraying
- Robot Spraying
- Drying & Quality Control
- Color Chart Printing
- Color Sample Mounting
- Cutting & Finishing
- Individual Self-Adhesive Bag
- Final Packing
Fan-deck manufacturing
Fan Deck Production — Coating Machine
- Coating Machine Application
- Drying & Quality Control
- Color Code Printing
- Reverse-Side Color Key Printing
- Cover Printing
- Collation & Assembly
- Pivot Screw Installation
- Fan Deck Box Insertion
- Box Shrink Wrapping
- Final Packing
Final packing and distribution
Planning a Color Chart or Fan Deck Program?
Tell us about your paint system, color standards, finish types and quantities. PHOENiX Sample can help develop a consistent presentation program.