Bug with rasterisation in Adobe Illustrator?
Hi All,
I hope someone can shed some light on a situation that I have discovered recently. It may be a bug or just the way that Illustrator has been written, but it had me chasing my tail for several months.
A little background
We got a new label printer at work, and through trial and error we figured out that sending rasterised PDF gave us the best print results. The rip attached to the printer allows us to substitute any spot colours that have been preserved in the rasterised file.
The problem
We started experimenting with Illustrator's rasterise function, which enables users to rasterise their vector layouts whilst preserving spot colours (instead of building from scratch), but we discovered a problem. It seems that it only supports 4x spot colours (properly). Every time I try and use more than 4 spot colours it breaks and seems to overprint entire channel for any number above 4. To illustrate this I have created a dummy and retraced my steps
The process
This is a screen shot of my illustrator file showing CYMK + 6 spot colours. In order to rasterise you go to the Object menu and select Rasterize, select your colour space etc and select preserve spot colours.



When you do this with 4 or less colours and save as a PDF you get the desired result:

But when you do it with 5 or more you get a result like the below. As you can see only the grey spot is showing (unless you turn overprint preview on). These have no overprint set at all so you wouldn't expect any overprints to happen:

I hope someone can help here, I would ideally be able to substitute more than 5 spot colours!

