Inside the Paint Lab: How Wausau Supply Perfects Custom Color Matching
When a customer, or a potential customer, requests a paint sample and asks for a perfect match, the process behind the scenes is far more technical (and fascinating) than most people realize. At Wausau Supply Company’s paint lab, precision and speed are the name of the game, and Paint Mixologist Mike Butt has been mastering this craft since 2006.
Step 1: The First Look
It all starts when a request arrives. Sometimes it’s an actual chip; other times, it’s a reference to a color from a major brand like Benjamin Moore. Mike’s first step is simple: check if the color already exists in the lab’s extensive color deck. Over the years, thousands of colors have been matched and cataloged, so there’s a good chance it’s already in the system.
Step 2: How Does a Spectrophotometer Measure Paint Color?
If the color isn’t in the deck, Mike turns to technology: a spectrophotometer. This device reads the color and provides an objective measurement. “I call it
the most honest tool in the lab,” Mike says. “Everyone sees color differently, so this takes the guesswork out.” The spectrophotometer compares the sample against a database of more than 7,000 colors, calculating how close the match is using a metric called delta.
What’s a Delta in Color Matching?
A delta measures color difference. At Wausau Supply, Mike’s goal is to keep matches within one delta, a level so precise that most people can’t detect the difference. For reference, the human eye typically notices differences at two deltas. “Sometimes I can see half a delta,” Mike admits, thanks to years of experience and bright lab lighting.
Step 3: Creating the Formula
If the color isn’t in the system or needs adjustment, Mike creates a custom formula using L*a*b values: lightness, darkness, and tint, rather than RGB codes. Once perfected, the formula is named, entered into the system, and assigned an item number for tracking. This step ensures consistency across all locations, so a color matched today can be reproduced years later in Stuart, Iowa or Rapid City, South Dakota.
How Long Does Custom Color Matching Take? Speed Matters
Matching colors isn’t just about precision; it’s also about turnaround time.
“Everything that comes in today, I try to get out the same day,” Mike says. “I’ve challenged myself to do 20 samples in a day and I’ve done it.”
That speed can make a big impression. During one facility tour, a group handed over a sample, and by the time they left that afternoon, Mike had it sprayed and ready.
From Samples to Jobs
Custom matches don’t guarantee a sale, but they often lead to big projects. The lab handles roughly 5,300 custom matches a year, which comes out to 3,800 gallons just in samples. These projects range from local coffee shops to national chains like Pizza Ranch, Pizza Hut, Dunkin’ Donuts, and even a house across the street from Lambeau Field. “Every time I drive by Lambeau, I tell people, ‘We did that!’” Mike says proudly.
Possible to Match? Challenges and Limitations
Not every color is possible. Bright neon shades, for example, are out of reach because Wausau Supply uses natural mineral-based colorants, metal oxides and crushed rock, rather than synthetic pigments.
“You don’t see too many neon rocks out there,” Mike jokes. Still, the lab’s palette spans thousands of colors, offering plenty of options for customers.
Why It Matters
Once a color is matched and entered into the system, it becomes part of Wausau Supply’s permanent library. Even a decade later, the same formula can be pulled up and reproduced. That reliability is critical for builders and developers who need consistency across projects.
Mike’s Motto
“We don’t turn anyone away,” Mike says. “If we can match it, we’ll give it a shot. If we can’t, we hope they’ll accept something close because they want our product and finish.”
From precision instruments to creative problem-solving, Mike Butt proves that the paint lab is where science meets art, ensuring every project gets the perfect color, every time.