Technical Support

Description:
This occurs when colors appear out of alignment on the final product.

Cause:

Improper plate mounting, worn & wrong printing underlays rollers, or press settings.

Solution:

Double-check plate alignment, ensure rollers are in good condition, and fine-tune press settings for accurate registration.

Description:

Freshly printed materials smudge if the ink hasn't dried properly.

Cause:

Ink viscosity too high, improper drying settings, or excessive pressure during printing.

Solution:

Adjust ink viscosity for better flow, optimize drying temperature and time, and reduce printing pressure if necessary.

Description:

A faint duplicate image appears on the backside of the printed sheet.

Cause:

Ink not drying completely, excessive ink application, or unsuitable paper for the ink type.

Problems & wrong settings in the inking system

Solution:

Ensure proper drying with appropriate settings, control ink application, and choose paper compatible with the ink for better absorption.

Description:

A faint duplicate image appears on the backside of the printed sheet.

Cause:

Ink not drying completely, excessive ink application, or unsuitable paper for the ink type.

Problems & wrong settings in the inking system

Solution:

Ensure proper drying with appropriate settings, control ink application, and choose paper compatible with the ink for better absorption.

Description:

Tiny fibers from the paper surface are pulled up during printing, creating an unwanted textured effect.

Cause:

Paper with a weak internal bond or using excessive ink tack.

Solution:

Choose paper with a stronger internal structure, or reduce ink tackiness to minimize paper fiber disruption.

Description:

Ink pigment does not bind to the paper and comes off easily by rubbing

Cause:

The paper stock might be too absorbent, causing the ink vehicle to soak in too quickly.

The ink itself might be formulated incorrectly, or might be too thick or incompatible with the paper.

The press speed might be too high, not allowing enough time for the ink to dry completely before the sheets stack.

Solution:

Use less absorbent paper
Ensure fountain pH is between 4.8 to 5.5
Use Stronger and Fast-setting Ink

Description:

Ink film remains wet &/or tacky to the touch

Cause:

The type of ink itself can play a big role. Inks that dry through oxidation (like oil-based inks) tend to dry slower than others
Excessive moisture on the printing plate or using too much dampening solution can hinder ink drying.
Low temperatures and high humidity in the printing environment
If printed sheets are stacked too closely right after printing, especially large sheets with a smooth surface

Solution:

Avoid addition of any non-drying compounds.
Avoid using highly acidic paper.
Ensure fountain pH is between 4.8 to 5.5
Avoid excess fountain solution onto the plate.

Description:

Printed Ink film appears dry but gets smudged when rubbed.

Cause:

The ink itself might be lacking the proper additives. This could be insufficient wax or slip agents
Incorrect ink fountain settings (too much ink applied)
Inappropriate ink for the paper type (ink dries too slowly for absorbent paper)
Issues with press settings like drying temperature

Solution:

Reduce fountain solution feed.
Ensure fountain pH is between 4.8 to 5.5
Use smoother paper.
Print with optimum ink release

Consult ink manufacturer.

Description:

Ink patches showing on non-image areas on the print.

Cause:

Ink-water imbalance: This is the most common culprit.
Improper plate development
Dirty rollers or ink pan
Glazed blanket or rollers
Incorrect roller settings

Solution:

Ensure fountain pH is between 4.8 & 5.5.
Use stronger ink and run with reduced release.
Check plate wear-off.
Correct Inkers and Dampers setting

Description:

Blemishes in the Printed Ink Film, especially for Solid Image Area

Cause:

Ink: Unground pigments or dried ink skin in the ink fountain.
Paper: Dust or fibers from the paper surface itself.
Press environment: Dust particles floating in the air.
Press rollers: Degraded rollers that are disintegrating and leaving behind bits of material.

Solution:

Ensure there is no skin while putting ink into ink duct.
Clean rollers and blankets to remove dried ink
Inspect press room and press for cleanliness to avoid dust/contamination

Use paper having good pick strength to avoid fluffing.

Description:

Constant film weight cannot be maintained on print

Cause:

Improper ink/water balance: If the ink-water mix is off, the ink won't emulsify correctly, affecting its drying and adhesion.
Ink viscosity: Ink that's too thick or thin can struggle to transfer and adhere to the paper.
Paper surface: Highly absorbent or improperly treated paper surfaces may not accept the ink effectively.

Solution:

Adjust the ink/water balance: A printing professional can test and adjust the fountain solution to achieve the optimal ink-water mix.
Change ink viscosity: The ink supplier can recommend an ink with a better viscosity for the specific paper and printing conditions.
Surface treatment: For certain papers, a pre-press treatment might improve ink adhesion.

Description:

Dot gain refers to the unwanted increase in size of tiny ink dots that make up images causing the printed matter to lack sharpness

Cause:

Ink: Viscosity, tackiness, and thickness of the ink film.
Press: Printing pressure, speed, and blanket condition.
Paper: Porosity and absorbency of the paper.

Solution:

Calibration: Creating printing profiles that account for expected dot gain with specific press, ink, and paper combinations.
Prepress adjustments: Adjusting image data in prepress software to compensate for anticipated dot gain.

Description:

Light tint appears on unprinted parts of stock and water marks spoil printed areas

Cause:

Ink-Water Imbalance: Too much dampening solution or ink that isn't compatible with the fountain solution can cause excessive mixing.
External factors: Temperature, humidity, and even the type of paper being used can affect the ink-water balance.

Solution:

Adjusting Ink and Dampening: A skilled press operator will constantly monitor and adjust the ink and fountain solution levels to maintain the right balance.
Ink and Fountain Solution Choice: Using compatible inks and fountain solutions formulated for each other can help prevent emulsification.

Description:

Fading refers to a loss of color intensity over time

Cause:

Ink: 1) Low lightfastness inks: Certain colors, especially bright ones, may not be designed for long-lasting vibrancy.
Improper ink mixing: Ink suppliers might substitute pigments to achieve a color match, and these substitutes may fade faster.
Paper: 1) Absorbent paper: Highly absorbent paper can cause the ink to sink in, reducing the ink film on the surface and leading to faster fading. 2) Inconsistent paper stock: Variations in paper quality within a batch can lead to uneven ink holdout and fading.
Printing process: Uneven ink application: Improper press calibration or roller pressure issues can result in patchy ink coverage that fades unevenly.

Solution:

Use high-quality inks formulated for lightfastness, especially for important documents or displays.
Work with a reputable ink supplier who uses the specified ink formulations.
Choose paper with a good ink holdout property suitable for the desired print quality and longevity.
Ensure proper press calibration and ink application for consistent color and coverage.
If fading is a major concern, consider using a protective coating on the printed material.

Description:

The printed area lacks the expected shine or luster compared to the desired result.

Cause:

Paper: Glossy paper itself can be affected by the printing process, with ink slightly dulling the surface.
Ink: Improper ink selection, particularly low-gloss inks, can contribute to a less shiny finish.
Drying: Insufficient drying time or incorrect drying settings can leave the ink film uneven, affecting gloss.
Dampening: Excessive dampening solution can disrupt the ink-paper interaction, reducing gloss.

Solution:

Paper: Choose a higher-gloss paper stock specifically designed for offset printing.
Ink: Consult your ink supplier for inks formulated for high gloss on your chosen paper.
Drying: Adjust drying settings (temperature, airflow) for optimal ink drying and film formation.
Dampening: Reduce dampening solution to minimize its effect on the ink film.

Description:

Refers to a situation where you're using more ink than expected to achieve the desired print quality.

Cause:

Improper ink-fountain settings: Incorrect ink film thickness due to excessive or insufficient ink feed from the fountain.
Ink viscosity: Ink that's too thick or thin won't transfer properly.
Fountain solution imbalance: The balance between ink and water (fountain solution) is crucial for proper transfer. Too much water can wash away ink.
Improper press settings: Impression pressure, blanket settings, and roller settings can all impact ink transfer.
Substrate: Printing on highly absorbent or non-absorbent paper might require adjustments.

Solution:

Adjust ink-fountain settings: Consult your press manual for optimal settings based on ink type and job requirements.
Check ink viscosity: If necessary, use ink conditioners or a different ink series.
Monitor fountain solution: Maintain the recommended water-to-alcohol ratio for your press and ink.
Refine press settings: Fine-tune impression pressure, blanket settings, and roller settings for optimal ink transfer.
Adjust for substrate: Use specific inks or adjust settings for non-standard paper types.

Description:

Fine spray of ink misting off the rollers during operation. This can cause issues with print quality and overall press cleanliness.

Cause:

Ink-water imbalance: The delicate balance between ink and fountain solution (water-based) is crucial. Too much ink or too little water can lead to misting.
Ink properties: Ink with low viscosity (too thin) or poor tack (stickiness) can be thrown off the rollers more easily.
Improper roller settings: Worn rollers, misaligned rollers, or incorrect pressure between rollers can contribute to misting.
Environmental factors: Low humidity in the pressroom can increase ink misting.

Solution:

Adjust ink-water balance: A qualified press operator can fine-tune the ink and fountain solution settings to achieve the optimal balance.
Change ink properties: If necessary, a different ink with higher viscosity or tack may be used.
Inspect and adjust rollers: Worn rollers should be replaced, and roller settings should be checked and adjusted for proper pressure and alignment.
Increase pressroom humidity: Maintaining a proper humidity level can help prevent ink misting.

Description:

Muddy halftones appear as a loss of detail and definition in areas with tonal variations (highlights to shadows). The image looks dull and lacks crispness.

Cause:

Ink-water imbalance: Too much ink or lack of dampening solution can lead to ink filling in the halftone dots, reducing detail.
Plate processing issues: Improper exposure or processing of the printing plate can cause uneven ink transfer.
Press factors: Worn blankets, incorrect pressure settings, or excessive ink film thickness can all contribute to muddy halftones.
Paper stock: Highly absorbent paper or improper ink formulation for the paper can cause ink to spread excessively.

Solution:

Adjust ink and water balance: A press operator needs to find the right balance between ink and water for optimal ink transfer and detail.
Verify plate processing: Ensure proper exposure and processing of the printing plate for clean ink transfer.
Inspect press components: Check blanket condition, pressure settings, and ink film thickness for any issues.
Select appropriate paper and ink: Choose paper compatible with the ink and adjust ink formulation if necessary.

Description:

This happens when the image area on the printing plate deteriorates during printing. This reduces print quality and shortens the plate's lifespan.

Cause:

Excessive pressure: Too much pressure between the plate and the blanket can cause abrasion.
Contamination: Dirt, paper dust, or aggressive chemicals can wear down the plate image.
Incorrect plate handling: Rough handling or improper cleaning solutions can damage the plate surface.

Solution:

Press settings: Ensure proper pressure (plate-to-blanket squeeze) is set according to press and blanket type.
Cleanliness: Maintain clean blankets and rollers to minimize debris transfer. Use approved cleaning solutions for plates.
Plate selection: Choose plates designed for the desired print run length and ink type.

Description:

Ink failing to properly adhere to the ink rollers. This can cause uneven ink transfer and printing problems.

Cause:

Glazed rollers: Over time, rollers can develop a smooth, hardened surface that repels ink. This can be caused by improper cleaning, using harsh chemicals, or running the press with unbalanced ink and water.
Improper fountain solution: An acidic or imbalanced fountain solution can affect the ink rollers' ability to hold ink.

Solution:

Cleaning and conditioning: The rollers need to be thoroughly cleaned with appropriate solutions and conditioners to remove glaze and restore their ink-receptive properties.
Adjusting fountain solution: Check the pH and conductivity of the solution and adjust it according to the manufacturer's recommendations.

Description:

low scuff refers to ink that easily rubs off the printed sheet.

Cause:

Ink film issues: Ink that dries too slowly, has poor ink-water balance, or isn't formulated for the paper type can all contribute to low scuff.
Paper properties: Highly absorbent paper or paper with a low pH level can affect ink drying and lead to scuffing.
Press settings: Excessive water on the plate, too much ink application, or improper drying settings can also be culprits.

Solution:

Adjust ink and fountain solution: Consult your ink supplier for inks specifically designed for high scuff resistance and adjust the fountain solution for optimal ink-water balance.
Paper selection: Choose paper with a good surface for ink adhesion and a neutral pH level.
Press adjustments: Reduce ink application, optimize water balance, and ensure proper drying settings like infrared drying.

Description:

Wet ink transfers from a freshly printed sheet to the back of the sheet above it in the delivery pile. This can result in smudging, marking, or even sticking of sheets together.

Cause:

Slow Drying Ink: Ink that takes too long to dry on the paper is more prone to set-off. This can be caused by incompatible ink and paper combinations, high humidity, or excess fountain solution.
Improper Ink Application: Too much ink laydown can increase drying time and lead to set-off.
Insufficient Powder Application: Anti-set-off powder helps create space between sheets and absorbs excess ink. Low powder application can leave sheets in direct contact, promoting set-off.
Delivery Stack Pressure: High pressure on the delivery pile can force wet sheets together, causing set-off.

Solution:

Adjust Ink and Paper: Use inks formulated for faster drying on the specific paper stock you're printing on.
Control Pressroom Conditions: Maintain a moderate humidity level in the pressroom to aid ink drying.
Optimize Ink Application: Ensure proper ink film thickness is applied, not too heavy.
Anti-Set-Off Powder: Apply the recommended amount of anti-set-off powder for effective separation and ink absorption.
Delivery Stack Management: Reduce pressure on the delivery pile by adjusting stacker settings or using lower stack heights.