Why Colour Variance Happens — and How Bodyshops Can Prevent It
Guidance from Independent Paint Supplies
Colour variance is one of the most common — and costly — challenges faced by commercial Bodyshops and body shops. Even with the correct paint code, two panels can look noticeably different once the vehicle leaves the booth. This leads to rework, delays, dissatisfied customers, and in some cases, rejected insurance repairs.
Understanding why colour variance happens is the first step. Knowing how to prevent it is where professional Bodyshops gain a real competitive advantage.
At Independent Paint Supplies, we work closely with commercial Bodyshops to reduce colour-related issues and deliver consistent, repeatable results.
What Is Colour Variance?
Colour variance occurs when a newly painted panel does not visually match the surrounding panels, even though the correct manufacturer paint code has been used. Variance may only be visible in certain lighting conditions, but that’s often enough for customers, insurers, or quality controllers to flag a problem.
Modern automotive finishes — especially metallics, pearls, and tri-coats — have made colour accuracy more challenging than ever.
The Main Causes of Colour Variance in Commercial Bodyshops
1. Paint Code Variations
Vehicle manufacturers often have multiple variants for the same paint code. These variants account for:
- Factory differences
- Production batch changes
- Model year updates
Using the paint code alone without checking variants is one of the most common causes of mismatch.
Prevention:
Always check available colour variants and spray test panels before committing to the repair.
2. Inconsistent Mixing and Ratios
Even small deviations in mixing ratios can cause noticeable differences in tone, depth, or flop.
Common issues include:
- Inaccurate weighing
- Rushed mixing
- Poorly maintained scales
- Inconsistent use of thinners or hardeners
Prevention:
Use calibrated mixing equipment, follow manufacturer mixing guidelines precisely, and standardise mixing procedures across all technicians.
3. Spray Technique Differences Between Technicians
Two technicians can spray the same paint differently and produce different results. Factors include:
- Gun distance
- Spray angle
- Overlap pattern
- Trigger control
- Application speed
These differences directly affect metallic orientation and colour depth.
Prevention:
Standardise spray techniques within the workshop and ensure technicians are trained to apply finishes consistently, especially on metallic and pearl colours.
4. Incorrect Spray Gun Setup
Gun setup plays a major role in colour consistency. Variance can be caused by:
- Incorrect air pressure
- Wrong nozzle size
- Uneven fan pattern
- Poor atomisation
Prevention:
Set up spray guns to manufacturer specifications and regularly check airflow, pressure, and fan patterns. Consistency is key across all bays.
5. Environmental Conditions
Temperature, humidity, and airflow inside the booth can all influence how paint lays down and cures.
Issues often arise from:
- Painting outside recommended temperature ranges
- High humidity affecting metallic orientation
- Inconsistent booth airflow
Prevention:
Monitor booth conditions closely and only spray when conditions fall within the paint system’s recommended parameters.
6. Substrate and Primer Colour
The colour underneath the basecoat significantly impacts the final appearance. Using the wrong shade of primer or sealer can cause:
- Darkening or lightening of the finish
- Reduced coverage
- Colour distortion
Prevention:
Use the correct shade of primer or sealer recommended for the colour being applied, particularly for lighter and vibrant colours.
7. Lack of Blending
Even a perfectly matched colour can appear different when applied to a single panel without blending into adjacent panels.
Prevention:
Blend into neighbouring panels whenever possible, especially on visible areas. Proper blending remains one of the most effective ways to eliminate visible variance.
How Independent Paint Supplies Helps Bodyshops Reduce Colour Issues
At Independent Paint Supplies, we don’t just sell paint — we support commercial Bodyshops with practical, real-world solutions.
We help Bodyshops by:
- Supplying trade-grade automotive paint systems with proven consistency
- Providing access to accurate colour matching tools and variants
- Advising on primer, basecoat, and clear coat combinations
- Supporting workshops with process standardisation
- Helping reduce rework, material waste, and downtime
Our goal is to help Bodyshops achieve first-time-right results, even in high-volume repair environments.
The Cost of Ignoring Colour Variance
Failing to address colour variance doesn’t just affect appearance — it affects profitability.
Consequences include:
- Increased rework and labour costs
- Paint and material waste
- Delayed vehicle turnaround
- Customer complaints
- Insurance repair rejections
- Damage to workshop reputation
In a competitive market, consistency is not optional — it’s essential.
Guidance from Independent Paint Supplies
Colour variance is rarely caused by a single issue. It’s usually the result of small inconsistencies adding up across the repair process.
Commercial Bodyshops that invest in:
- Proper procedures
- Consistent equipment setup
- High-quality paint systems
- Reliable supplier support
are the ones that deliver repeatable, professional results.
Independent Paint Supplies is proud to support commercial Bodyshops with the knowledge, products, and expertise needed to get colour right — every time.