Kwality Chemical Industries Pvt.Ltd.

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"A Government Recognised One Star Export House"

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TROUBLESHOOTING/PROBLEM-SOLVING

Problem

Symptom

Solution

Backing

 

Constant film weight cannot be maintained on print.
Ink does not follow duct rollers. .

  1. Ensure there is sufficient ink in the ink duct.
  2. Add KA/1658 Flow Improver to the ink. (Max 5%)
Chalking

 

Ink pigment does not bind to the stock and comes off by mere rubbing. 

  1. Use less absorbent paper. 
  2. Ensure fountain pH is between 4.8 to 5.5
  3. Use Higher Quality Ink (Stronger and Fast-setting)
  4. Use /2555 O.P. Medium to save printed sheets.
Dot Gain/ MuddyHalftones

 

Halftone dots increase in size causing the printed matter to lack sharpness. 

  1. Reduce ink release. 
  2. Check reproduction process/ plate/ blanket. 
  3. Ensure proper ink-water balance.
  4. Use stronger ink – Eg. Speedking. 
  5. Add KA/1726 Synthetic Medium. (Max 5%)
Emulsification/ Tinting

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

  1. Maintain proper ink-water balance. 
  2. Clean/check plate, correct if necessary. 
  3. Ensure fountain pH is between 4.8 & 5.5.  
  4. Add KA/1953 Thickening Powder to improve water resistance. (Max 2%)
Fading

 

Print changes strength or colour with time. 

  1. Check paper stock.
  2. Use Light-fast Inks in case of outdoor exposure. 
Gloss(Low)

 

Less gloss/reflection from printed image.

  1. Use smoother paper. 
  2. Reduce fountain solution feed. 
  3. Increase Ink film thickness slightly.
  4. Use Glossy ink – Eg. Speedking / Sigma / Spectra
Hickies

 

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

  1. Ensure there is no skin while putting ink into ink duct.
  2. Clean rollers and blankets to remove dried ink. 
  3. Inspect press room and press for cleanliness to avoid dust/contamination. 
  4. Use paper having good pick strength to avoid fluffing.
Mileage

 

More ink is consumed per impression than normal. 

  1. Adjust colour densities to optimum with satisfactory print quality. 
  2. Maintain proper ink-water balance.
  3. Use stronger ink – Eg. Speedking. . 
Misting/Flying

At high machine speed, a spray/fog/mist is visible in the air which finally covers entire parts of the press. 

  1. Use stronger ink with lower release.
  2. Check roller settings.
  3. Release optimum fountain solution. 
  4. Reduce the printing speed.
  5. Add KA/1918 Q.S.Tack Reducer. (Max 5%)
Picking of Paper

 

Particles torn from papers, paper coating scattered at irregular places. 

  1. Use paper having good pick strength. 
  2. Use less tacky blanket.
  3. Check print pressure.
  4. Reduce machine speed.
  5. Add KA/1918 Q.S.Tack Reducer. (Max 5%)
Plate Wear Off

Loss of image area meaning successive impression becomes weaker and weaker.
Especially common in long run jobs.

  1. Re-adjust the pressure of ink form roller and damping form roller.
  2. Check/Reduce Plate to Blanket pressure.
  3. Check quality of plate.
  4. Ensure fountain pH is between 4.8 to 5.5.
  5. Consult ink manufacturer to check grinding.
Roller Stripping

 

Steel rollers do not accept ink and remain blank at certain areas. 

  1. Reduce damping solution feed. 
  2. Ensure fountain pH is between 4.8 & 5.5.  
  3. Clean the rollers and copperize if reqd.
  4. Add KA/1953 Thickening Powder to ink. (Max 2%)
Rub Resistance/ Scuff Resistance
(Poor)

 

Printed Ink film appears dry but gets smudged/ transferred when rubbed. 

  1. Reduce fountain solution feed. 
  2. Ensure fountain pH is between 4.8 to 5.5
  3. Use smoother paper. 
  4. Print with optimum ink release. 
  5. Consult ink manufacturer. 
  6. Use KA/2555 O.P. Medium.
Scumming

 

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

  1. Ensure fountain pH is between 4.8 & 5.5. 
  2. Check plate wear-off. 
  3. Use stronger ink and run with reduced release.
  4. Correct Inkers and Dampers setting.
  5. Add KA/1726 Synthetic Medium. (Max 5%)
Set-off

 

Ink marks appear on the back of the next sheet in the delivery pile. 

  1. Reduce Ink release. 
  2. Use Higher Quality Ink (Stronger and Fast-setting) Eg. Speedking. 
  3. Reduce size of stacks. 
  4. Use K/2700 Kwalispray Powder in multicolour printing.
  5. Add KA/1214 Speedo Liquid Drier. (Max 2%)
Slow Drying

 

Ink film remains wet or tacky to the touch. 

  1. Avoid addition of any non-drying compounds. 
  2. Avoid using highly acidic paper. 
  3. Ensure fountain pH is between 4.8 to 5.5
  4. Avoid excess fountain solution onto the plate. 
  5. Add K/1202 Liquid Drier. (Max 2%)
Trapping

Subsequent colours on multicolour job do not transfer properly, resulting in poor Colour balance. 

  1. Check temperature of the ink roller. 
  2. Make sure inks are printed in decreasing tack order.
  3. Check ink release of subsequent colours.
  4. Maintain proper ink-water balance.
  5. Check the strength and viscosity of ink by consulting ink manufacturer. 
  6. Add KA/1918 Q.S. Tack Reducer in subsequent colours.    (Max 5%)