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Trouble
Shooting Guide for Sheetfed offset printers
|| Trouble Shooting Guide For Web
offset heatset printers
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Blistering
A moisture explosion in the paper-looks
like a bubble on both sides of web and generally
in heavy coverage areas.
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| * Oven heat is too high. |
| * Excess dwell time in oven. |
| * Defect in paper causing excessive
moisture content, improper density or
base. |
| * Pigment strength of ink is too low,
requiring more ink than normal to be
carried in heavy coverage areas. |
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| * Reduce oven temperature. Consult
ink manufacturer to provide ink that
can be cured at a lower temperature. |
| * Correlate press speed. Web dwell
time in dryer, and chill roll temperature
to optimum performance levels. |
| * Blistering may not occur across
the full machine reel. Run roll from
different paper machine position. Run
a substitute stock. Consult paper manufacturer
and reject if necessary. |
| * Consult ink manufacture to adjust
pigment strength as needed. |
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Blocking
Undesired adhesion between printed signatures
or sheets in a bundle or load causing them
to stick together.
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| * Refer to Inadequate Drying section
of this guide |
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Dot Sharpness
Printed screens and reverses are plugged,
appearing muddied, and show higher values
than the "Prog" proof shows.
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| * Too much form-to-plate, plate-to-blanket,
or blanket-to-blanket pressure. |
| * Doubled or slurred dots. |
| * Ink body is too long and soft and
is squashing at the point of impression. |
| * Ink is too water receptive. |
| * Poorly ground ink. |
| * Piling. |
| * Plate was not sharp enough to compensate
for normal dot spread from film to plate
to press. |
| * Improper ink/water balance. |
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| * Check settings and correct to proper
pressure. |
| * Adjust plate-to-blanket pressure.
Make sure blanket is secure. Check press
for roller slippage or mechanical stability
at high speeds. |
| * Consult ink manufacturer to provide
stiffer ink. |
| * Consult in manufacturer |
| * See PILING section of this guide. |
| * Have cameraman and platemaker cooperate
in making sharper halftones, negatives,
positives and plates. |
| * Adjust ink and water settings. Consult
ink manufacturer. |
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Inadequate Drying
Ink remains tacky during press delivery
and bindery operations, resulting in set-off,
marking, or blocking.
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| * Dryer temperature too low for speed
of web. Insufficient solvent being released
from ink film. |
| * Ink film thickness excessive. |
| * Inadequate evacuation of solvent
vapors clinging to web as it leaves
dryer. |
| * Chill system not working properly;
ink resins are not setting hard enough. |
| * Stock is not porous enough or has
too high water content. |
| * pH/conductivity of fountain solution
is incorrect. |
| * Ink takes an too much water. |
| * Plate dampening is uneven. |
| * Ink film is only surface dried in
oven and still wet underneath. After
chilling ink solvent will work its way
toward surface causing set-off. Most
likely to occur with heavier than normal
ink film thickness, very non-absorbent
stocks, or high oven temperature. |
| * Ink films do not dry at normal dryer
temperature. |
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| * Increase dryer temperature to specification
level. |
| * Run less ink or consult in manufacturer
to increase strengths for this purpose. |
| * Increase velocity of air in air-knife
scavenger at dryer exit. |
| * Lower chill roll temperature. Caution:
Watch for chill roll condensation. |
| * Switch stock to correct porosity
or water content. |
| * Adjust pH/conductivity to proper
level. Refer to Ink Manufacturer. |
| * Consult ink manufacturer for proper
adjustment. |
| * Keep dampeners clean and free from
accumulated dirt. Prevent drafts, check
windows, vents, and forced air systems. |
| * Reduce speed of press, Adjust oven
temperature. |
| * Consult ink manufacturer for ink
that dry at lower temperatures. |
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Gloss
There is a decrease in the normal reflection
of light from the dried ink surface whether
observed visually, or read via glossmeter.
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| *Paper too ink absorbent. Paper surface
too rough and grainy.has poor gloss. |
| * Dryer temperature too high |
| * Press dampeners - too much water
being introduced in to inking system.
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| * Ink film thickness too low. |
| * Excessive ink vehicle penetration
into web. |
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| * Consult paper manufacturer to obtain
stock with more ink hold out obtain
stock with smoother surface better gloss. |
| * Consult ink manufacturer to obtain
low temperature inks. Decrease press
speed to allow decrease of oven temperature. |
| * Cut back on amount of fountain solution
used. Consult ink manufacturer of decrease
water receptivity of ink. |
| * Increase ink film thickness being
carried on web. |
| * Reduction of heat in dryer. Increase
press speed to reduce oven dwell time,
maintain sufficient chilling capacity.
Consult ink manufacturer, obtain inks
with better hold-out. |
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Hickies
Doughnut shaped or irregularly shaped white
spots surrounding a small spot of ink.
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Doughnut Shaped Hickies.
* Dried ink particles. |
| * Flakes of inking rollers. |
| * Glazed rollers. |
| * Disintegration of dampener roller
sleeves or rollers due to wear. |
| * Foreign particles (dirt) from ceiling
have fallen into press. |
| * Loose paper dust on web. |
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| * Avoid dried ink skin when removing
ink from cans or kits. Protect ink remaining
in a can or kit from oxidation drying
and formation of ink skin by applying
a sheet of paper or plastic on top of
it. Clean the press thoroughly and remove
all dried ink in the fountain or on
the rollers before inking up the press.
Prevent the ink in the ink fountain
from mixing with dried ink around tie
ink fountain edges. Prevent ink from
caking on the ends of rollers by lubrication
and manual washing. Use a leather covered
or a grained rubber roller. This will
pick up hickies that are passed on to
the plat. Remove the leather-covered
rollers and clean them thoroughly as
needed. |
| * Recondition the rollers and drums.
Replace if necessary. |
| * Use one of the specially formulated
glaze-removing materials or remove the
form rollers, and alternately scrub
the form rollers and the drums with
pumice powder and ink solvent to remove
the glaze. |
| * Replace suspect roller sleeves or
rollers with new ones. |
| * Vacuum clean the ceiling and everything
overhead where dirt can accumulate.
Paint the ceiling if necessary, or hang
plastic sheeting over the press to catch
the falling particles. Use a leather-covered
or a grained rubber roller. This will
pick up hickies that are passed on to
the plate. Remove the leather-covered
rollers and clean them thoroughly as
needed. |
| * Install vacuum sheet cleaner. Consult
paper manufacturer. |
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Inconsistent Color
Reproduction
Color hues when printed do not match proofs.
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* Paper Proofed on is not the same
as that being printed. paper being
printed is more absorbent.
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| * Excessive heat in dryer results
in too much penetration of the ink resin,
resulting in loss of gloss-ink is overdried. |
| * Special, spot color does not match
proof. |
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| * Adjust ink film thickness to that
of the proof. Consult manufacturer to
adjust color hue and hold-out of ink
to match the proof on the actual paper
being printed on Consult paper manufacturer
to see if paper is available which more
closely duplicates the paper proofed
on. |
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* Reduce fryer temperature Increase
press speed.
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* Consult ink manufacturer.
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Ink / Water Balance
Frequent adjustments required on press to
maintain print quality.
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| * Excessive or insufficient dampening
solution being run. |
| * Fountain solution too weak or improperly
mixed. |
| * Improper dampening roller setting. |
| * Improper ink from roller setting |
| * Improper ink fountain setting. |
| * Weak ink, i.e. low color strength. |
| * Ink taking up too much water. |
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| * Reduce or increase dampener settings. |
| * Check pH/conductivity and adjust
accordingly. Refer to Ink Manufacturer.
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| * Re-set rollers. Be sure dampener
form rollers are driven by the vibrator
roller and not the plate. |
| * Conduct ink stripe test to check
form roller pressure. |
| * Adjust the amount of ink at fountain.
Allow adequate time for adjustment to
take full effect. |
| * Consult ink manufacturer for proper
adjustment. |
| * Consult ink manufacturer. |
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Ink Mileage
More ink used per impression than normal.
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| * Lack of control an color densities. |
| * Ink penetration into stock too rapid. |
| * Improper ink and water balance. |
| * Low pigmented inks. |
| * Excessive waste at start-up of run. |
| * Improper estimate of coverage from
job to job. |
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| * Adjust color densities to minimum,
consistent with satisfactory print quality. |
| * Consult ink manufacturer for ink
with more hold-out. Change to less porous
stock. |
| * Reduce amount of water carried. |
| * Consult in manufacturer for proper
tinctorial strength. |
| * Improve start-up procedures. |
| * Establish ink usage history so that
these figures can be used to more accurately
predict ink usage. |
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Marking
Streaks, tracks, or smudges on web due to
mechanical contact.
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| * Grater roller. |
| * Web bustle wheels. |
| * Improper air flow through oven causing
web to flutter and make contact with
oven apparatus. |
| * Chill roll not cool enough. |
| * Web temperature reached in the oven
is not high enough to drive off sufficient
ink solvents. |
| * Dryer does not have capacity to
properly handle press speeds reached
or type of work printed. |
| * Paper is very non-absorbent, very
little ink penetration occurs to provide
basis for binding to paper. |
| * Ink film thickness is too great. |
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| * Install grater roller with sharper
points. Increase pigment strength of
ink so as to decrease in ink film thickness
carried on web. |
| * Move wheels so as to contact non-image
areas only. If moving wheel is not possible,
apply teflon tape to lessen abrasiveness
of wheel surface. |
| * Consult oven manufacturer for proper
adjustment or adjust web tension. |
| * Reduce chill roll temperature so
that post-chill roll web temperature
is 90F or less. Recommended chill roll
water temperature 72-75 F. Caution:
If chill rolls are too cold, condensation
can occur. Reduce oven temperature to
minimum necessary to get the web through
chilling and press folding delivery
operation. |
| * If flame impingement drier used,
adjust flame tips to impinge properly.
If high velocity forced air drier used,
raise circulating air temperature in
oven until marking is eliminated. Caution
: Remember paper will burn at 451 F
and can scorch at lesser temperatures.
Decrease press speed. Increase air velocity
through oven so as to remove air and
vapor layer clinging to moving web.
Consult in manufacturer to obtain faster
drying ink. |
| * Consult dryer manufacturer. |
| * Consult paper manufacturer, change
paper. |
| * Raise air temperature circulating
in dryer. Reduce press speed to increase
dwell time in dryer. Increase air velocity
circulating to help remove solvent vapor
layer. Consult in manufacturer, change
to faster drying inks. |
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Misregister
In the press runing direction and side to
side, after the press has been set for proper
registration, trouble arises when some condition
prevents consistently good register.
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Misregister
in the press running Direction : |
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| * One or more plates are cocked or
are not properly set on their cylinder. |
| * One or more plates are printing
longer or shorter than the others. |
| * Uneven blanket packing. If one of
the printing units is not pulling the
web fast enough, web tension between
it and the following unit will build-up
until the web snaps back, causing misregister.
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| * Web tension is too low; the higher
the tension, the better the register. |
| * Web press tension changes during
run because infeed tension changes.
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| * Ink at the point of impression is
too high causing the web to follow the
blanket more than normal. This momentarily
increases the tension in localized areas
and as a result can affect running register.
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| * Paper pile on blanket changes blanket
diameter. |
| * Paper roll out of round or having
flat areas therein. |
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| * Plates should be handled more carefully
on bending jig. |
| * Transfer the packing from blanket
to plate to shorten the print, or from
plate to blanket to lengthen the print.
Maintain good tension on the web. |
| * Adjust blanket packing until the
draws between the units are equal. |
| * Increase web tension in the infeed
section of the press. |
| * Equip presses with a constant-tension
infeed. |
| * Increase web tension. Reduce press
speed. Consult ink manufacturer for
tack reduction of ink causing problem. |
| * Wash blanket more frequently. Change
to paper that is more moisture resistant. |
| * Constant-tension infeed will help.
Increase distance traveled by the web
between infeed and the first printing
unit. Change to a roll that does not
have problem. |
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Misregister
Side-to-Side (more likely with wide webs 35+
Inches.) |
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| * Non-uniform moisture content the
web causes corrugation of roll, resulting
in side-to-side misregister. |
| * Welts caused by unwrapping rolls
in a high humidity area and allowing
them to stand for a long time. These
welts will occur no more than 25 mils
in to roll. The smoll amount of corrugation
will cause some side-to-side misregister
just after splicing. |
| * Paper varies in caliper across the
web . |
| * Web has edges due to moisture pick-up
while in the roll. |
| * Ink tack too high at point of impression.
Refer to Running direction Misregister
section of this guide. #6 under cause. |
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| * Increase distance traveled by the
web between the infeed and the first
printing unit. The longer this distance
and the higher the web tension, the
more uniform the web will be. Use a
preheater on the infeed and the first
printing unit to dry the paper, even
out the moisture content and flatten
the web. Equip press with a curved roller
to spread and flatten the web. |
| * Remove outer 25 mils of paper. Do
not unwrap rolls until just before going
to press. |
| * Consult paper manufacturer. |
| * Keep rolls protected form atmospheric
changes until they are mounted on the
infeed stand. Increase distance traveled
by the web between the infeed and the
first printing unit. Increase web tension,
stretching the web tends to tighten
slack edges. Equip the press with a
curved roller on the infeed to spread
and flatten the web. Adjust the eccentric
- mounted infeed roller to balance edge
tension. |
| * Refer to Running Direction Misregister
section of the guide 6# under solution. |
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Misting / Slinging
Misting - Excessive amount of ink being
thrown from ink train rollers described
as fine droplets.
Slinging - Ink being thrown from rollers
in filaments.
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| * Too much ink on rollers |
| * Improper Ink and water balance. |
| * Ink is too long in body. |
| * Rollers are incorrectly set or in
poor condition. |
| * Roller train too hot. |
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| * Make press adjustment to decrease
amount of ink carried or consult ink
manufacturer to increase ink strength
and carry less ink on rollers. |
| * Adjust ink and water balance to
proper setting. |
| * Consult ink manufacturer. |
| * Reset rollers based on manufacturer's
specifications. Replace rollers if in
poor condition. |
| * Reduce temperature or increase flow
of cooling water through ink train rollers. |
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Mottled Solids
Printed solid area is not uniform (smooth)
in appearance or density.
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| * Stock has non-uniform surface formation. |
| * Too much printing pressure. |
| * Improperly set ink form rollers
or rollers in poor condition. |
| * Improper ink or water balance. |
| * Blanket has not been changed for
a long time and has become worn and
rough in certain areas. |
| * Poor ink transfer. |
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| * Get better grade of paper. Consult
ink manufacturer to provide weaker ink
and minimize penetrating tendencies. |
| * Reduce printing pressure. |
| * Check condition and reset ink form
rollers to specifications. |
| * Adjust to proper ink and water balance. |
| * Replace with new blanket. |
| * Consult ink manufacturer. |
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Picking / Linting
Linting - Pulling fibers from uncoated stock.
Picking - Lifting of the coating form coated
stocks onto blankets, plates or rollers.
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| * Too much water reaching paper. |
| * Dampening solution concentration
too high. |
| * Paper surface trash, coating dust,
slitter or trimmer dust. |
| * Base stock picks. |
| * Pressure set too high for ink/stock
combination being used. |
| * Blanket is too tacky. |
| * Ink is too tacky for stock run. |
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| * Reduce dampener setting for proper
performance. |
| Adjust dampening solution mix. Consult
dampening solution manufacturer. |
| * Make tape pulls from blanket, consult
paper manufacturer. |
| * If serious, reject paper change
to more lint or pick-resistant stock
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| * Reduce impression pressure; repack
to manufacturer specifications. |
| * Consult blanket manufacturer. Treat
blanket or change to a less tacky blanket.
Check blanket wash. |
| * Consult ink manufacturer to lower
tack of ink. |
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Piling
Build up of paper coating lint, or ink on
rollers, blankets or plates.
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| Paper : |
| * See Picking / Linting section of
this guide. |
| INK : |
| * Ink is water logged due to insufficient
body or tack. |
| * Ink is poorly ground, contains a
coarse heavy pigment. |
| Mechanical |
| * Improper packing of cylinders or
rollers not set correctly. |
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| * See Picking / Linting section of
this guide. |
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| * Reduce dampener settings. Consult
ink manufacturer. |
| * Consult ink manufacturer.
Have ink reworked or reformulated. |
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| * Check specifications and adjust
it necessary. |
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Plate Blinding
(Loss of Image) Part or all of image on
plate does not take ink.
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| Mechanical |
| * Excessive amount of lint deposited
on place. |
| * Excessive plate-to-blanket pressure
causing plate wear. |
| * Improperly set ink and dampening
form rollers. |
| * Abrasive particles destroying image. |
| Chemical |
| * Too much acid in the fountain solution. |
| * Too much gum in fountain solution. |
| * Plate cleaners and / or scratch
removers have dried on plate image.
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| * Detergent remains or has somehow
entered the fountain system. |
| * Ink will not adhere to image area
due to excess amount of fountain solution
being accepted by the ink. |
| * Plate not completely developed. |
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| * See Picking / Linting section of
this section. |
| * Re-set to specifications. Use packing
gauge to check pressure. |
| * Roller could be too hard-check durometer.
Also check setting; re-set if too much
pressure exists. |
| * Check ink grind, fountain solution,
solvents, etc. Replace all contaminated
material. |
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| * Check pH/conductivity and adjust
to 4.0-4.5 pH. |
| * Re-etch plate and rub-up image areas
with press ink. Drain fountain solution
and refill with top water. If image
returns, replace top water with fountain
solution containing less gum. |
| * Always rinse plate thoroughly and
immediately after using such items. |
| * Make sure that all parts that come
in contact with cleaning detergent have
been thoroughly rinsed before re-installing
in press. |
| * Reduce dampener setting to minimum;
if problem persists consult ink manufacturer. |
| * Wash plate. If problem persists
have plate remade. |
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Poor Rub and
Scuff Resistance
Printed ink film appears dry but exhibits
poor rub and / or scratch resistance when
abraded.
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| * Too much water run on job or paper
too much water. |
| * pH of fountain solution too high. |
| * Ink not fully dry. |
| * Poor Paper coating integrity. |
| * Roughness of paper surface creates
poor rub between unprinted paper surface
and printed paper surface (e.g. some
dull coat type stocks.) |
| * Too much ink. |
| * Ink is not properly formulated for
rub resistance. |
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| * Reduce dampener setting. Change
paper. |
| * Very high pH/ conductivity is indicative
of too much acid in fountain solution
which can retard or prevent drying of
inks. Adjust pH/conductivity accordingly.
Refer to Flint Ink Corp. Technical Monograph
TM84-5 on conductivity. |
| * Refer INADEQUATE DRYING section
of this guide. |
| * Consult paper manufacturer. |
| * Consult ink manufacturer to provide
ink with better rub resistance. |
| * Lower level of ink carried. |
| * Consult ink manufacturer for adjustment. |
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Scumming
The non-image area of a lithographic plate
accepts ink in random areas.
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| * Low alcohol content in dampening
system. |
| * Glazed blanket, ink rollers, or
dampening rollers. |
| * Excessive printing pressure. |
| * Ink spreading into non-printing
areas. |
| * Plate improperly exposed to light
after being allowed to dry. |
| * Improper ink/water balance. |
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| * Bring alcohol content to correct
concentration. |
| * Clean thoroughly and recondition
per manufacturer's instructions. |
| * Make on-press adjustment to proper
pressures. |
| * Consult ink manufacturer to assure
ink is on-standard reformulate if necessary. |
| * Desensitize or remake plate. |
| * Refer INK/WATER Balance section. |
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Roller Stripping
Rollers do not accept inks.
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| * Fountain solution too acid. |
| * Too much water being run. |
| * Desensitized metal vibrator rollers. |
| * Glazed form roller. |
| * Too much dampening solution being
emuismed in ink. |
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| * Check pH/conductivity and gum concentration
levels of fountain solution. Refer to
Flint ink Corp. Technical Monograph
TM84-5 on conductivity. |
| * Reduce dampener setting. |
| * Clean rollers, copperize, wash thoroughly.
Then ink rollers and wash again. |
| * Remove rollers from press and deglaze
per manufacturer's procedure. Rinse
thoroughly. |
| * Consult ink and dampening solution
manufacturer |
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Tinting / Toning
Fine particles if ink transmitted by press
water dampeners to non-image areas of plate.
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| * Ink bleeding into fountain solution. |
| * Improper fountain solution concentration. |
| * Improper ink and water balance. |
| * Too much pressure between plate
and blanket. |
| * Improper setting or durometer of
dampener or ink rollers. |
| * Ink not sufficiently water resistant. |
| * Plate improperly exposed, developed. |
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| * Check concentration of alcohol or
alcohol substitute in fountain solution.
Consult ink manufacturer to reformulate
using non-bleeding pigment, if possible. |
| * Check pH/conductivity and adjust
to proper concentration. Refer to Flint
Ink Corp. Technical Monograph TM84-5
on conductivity. |
| * Check and re-set to manufacturer's
specifications. |
| * Check and re-set roller to manufacturer's
specifications; if rollers are old,
check durometer. |
| * Consult ink manufacturer. |
| * Check platemaking procedures; correct
if necessary. |
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Trapping
Cannot achieve good color coverage.
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| * Too much tack in relation to preceding
ink. |
| * Unequal press stability of inks.
Ink tacks up quicker than preceding
ink. |
| * Ink strength not balanced properly. |
| * Ink contains additive that creates
a film preventing succeeding ink layers
from adhering. |
| * Ink and water balance. |
| * Poor ink release from blanket. |
| * Improper register causing poor appearance. |
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| * Consult ink manufacturer. Reduce
tack of the ink that is not trapping
properly. |
| * Consult ink manufacturer to coordinate
stability of all ink color(s). |
| * Consult ink manufacturer. |
| * Consult ink manufacturer. |
| * Refer to MOTTLED SOLIDS section
of this guide. |
| * Consult blanket and / or ink manufacturer. |
| * See MISREGISTER section of this
guide. |
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Paper : |
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Web Breaks
Tearing of web as it travels through press-can
occur infeed to cut-off due to cut-off due
to (1) paper defects, (2) press settings,
or (3) ink.
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| * Excessive tension on one or both
edges of web due to loss of moisture
and shrinkage. |
| * Roll has dent or cut in end. |
| * Fiber cuts, hair cuts, wire holes,
wrinkles, slime spots, foam spots, calendar
cuts-Any one of these can start a tear. |
| * Bad mill splices |
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| * Keep roll completely wrapped until
ready to mount on roll stand. If the
rolls are stored, make sure wrappings
are undamaged. |
| * If dent is not deep, send or cut
it out until edges of the paper are
smooth. If the dent is deep, Print down
to the dent, stop the press, slab off
the damaged portion of roll, resplice,
and resume printing. If rolls are too
badly damaged. consult paper manufacturer. |
| * If defect are numerous consult paper
manufacturer. |
| * If problem is extensive. The paper
mill should be contracted. |
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Press : |
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| * Web tension set too high. |
| * Printing units or other press elements
may be out of line. This is indicated
if a proportionately large number of
web breaks occur in one section of the
press. An indication of misalignment
of press elements is the presence of
diagonal wrinkles in any span of web
in the press. |
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| * Decrease web tension. |
| * Have the press alignment checked
and corrected if necessary. |
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INK : |
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| * Printing tack of ink is too high
causing web to adhere to blanket and
follow it causing a tear and subsequent
web break. |
| * Body of ink is too long allowing
drippage from fountain nip onto web-below.
Web will follow blanket causing break. |
| * Pigment strength of ink is too low
causing ink fountain keys to be opened
up too much. As a result ink will drip
through ink fountain nip onto web below.
Web will follow blanket causing break.
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| * Ink slinging. |
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| * Consult ink manufacturer. |
| * Consult ink manufacturer. |
| * Consult ink manufacturer. |
| * Consult MISTING / SLINGING section. |
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