Probable CausesSolution
Heavy Ink Film WeightReduce ink film wt, use stronger ink, change over to faster curing ink
Dark color, opaque white, metallic inkRun thinner ink film, Decrease press speed, change the color sequence for multiple curing of dark color
Contamination of oil-based ink, residue of binding & washing agent on rollersCheck the changeover from oil based to UV, repeat the cleaning process & check curing on waste sheets
Incorrect ink water balanceToo much ink & water that does not harden the ink film. Minimum dampening is essential
Poor UV exposureClean or replace reflectors, Check UV lamp hours for output. Lamps should be changed after 1000 hours
Press speed too fastDecrease press speed, Reformulate or Change of ink
Probable CausesSolution
Low surface energy <38dynes/cmTreat the substrate with a water based or solvent based primer or else change to chemically coated stock
Ink film too heavyRun thinner ink film, Stronger ink, Change the ink to cure deeply.
Under-cure of underneath Dark InkLower ink film wt. Decrease press speed
OvercuringReduce UV power or multiple curing
Weak bonding of laminated stockCheck the lamination bonding
Probable CausesSolution
Check the substrateOdor may come from paper coating. Check the odor after cooling.
Improper ventilationCheck the suction, hot air extraction
High odor ink and OPVChange to low odor ink & OPV
Probable CausesSolution
Excessive spray powder usedWipe prints to obtain good lay
Distance between printing unit & curing unit is not optimizedOptimize the distance
Too high tack or viscosityReduce with a UV reducer
Poor flowReduce with UV reducer
Inappropriate substrateChange paper
Probable CausesSolution
Poor curingSlow down the speed
Poor layIncrease the flow by reducing viscosity, by increasing the temperature, add reducer or anti tack compound
Paper / Board too absorbentChange paper
Probable CausesSolution
Too much alcohol in fountCheck PH & reduce acidity. Reduce amount of fount
Fount solution is extracting emulsifier or sensitizer from paperChange paper
Coating solubilizes the inkCheck the ink formulation, avoid fanal shade pigment
Bleeding Sample

Bleeding Sample

Probable CausesSolution
Under-curedClean UV lamp, Check output of UV lamp, Distance between application & curing must be reduced,Reduce speed
Excess ink retention to obtain desired strengthIncrease the strength of the ink
High coating weightReduce the film weight
Low gramage substrateReduce stack height
Probable CausesSolution
Heavy film weightReduce film weight
Poor heat resistanceCheck the ink formulation
Multiple passes through UVReduce the time gap between the passes
Poor flexibility of topcoatUse a flexible varnish
Faulty substratePrime the substrate
Cracking Sample


Probable CausesSolution
OvercuredDecrease the lamp intensity, reduce inter-deck curing.
Defective substrateCheck the dyne value. Treat the substrate .Apply Corona or a primer.
Multiple passReduce the time gap between passes
Probable CausesSolution
PH value of dampening solution incorrect4.8-5.2 recommended
Plate inking roller set too firmly to the ink distributorAdjust the setting
Unsuitable dampening solutionMake fresh fount
Printing pressure too highReduce the pressure
Swollen plate inking rollers impairs rollingChange the plate
The ratio of water to ink feed is incorrectUse as little ink 7 water possible
Inking unit temp too high causing the dampening solution to evaporateIncrease the ink chilling device temp 2Degc above the condensation point on the ink duct around 23deg c
Incorrectly baked platesUse proper baked plate

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