In the printing production process, the printing net often encounters issues such as plug-in versions. These problems not only lower the quality of the print but also significantly reduce printing efficiency. What makes it worse is that the products printed by these outlets are typically from large clients, like Wahaha, Mengniu, and other fast-moving consumer goods companies. These orders are large in volume, and during the printing of thousands of sheets, the press has to stop frequently for plate cleaning. As a result, downtime increases, productivity drops, and carton production suffers. So, how can we effectively address the issue of plug-in problems?
Generally, fast-moving consumer goods require more packaging with finer details. This makes the problem of ink buildup or plugging even more critical. The main causes of plug-in issues are usually related to ink, printing plates, and operational errors.
First, Ink-Related Issues
1. Poor ink fluidity. During the printing process, some operators tend to adjust the ink flow by reducing the speed, which leads to an excessive amount of ink being stored between the anilox roller and the rubber roller. While this method may work well for full-page printing, it can cause over-inking on fine details, resulting in plugged dots or missing characters.
Solution: To prevent this, ensure the ink flows smoothly. Adjusting the air pressure of the ink pump can help improve ink flow and avoid over-inking.
2. Ink dries too quickly. When ink transfers from the anilox roller to the printing plate, if it dries too fast before reaching the paper, it can stick to the plate, causing a plug-in effect.
Solution: If the ink on the plate feels dry and hard to rub off, it’s likely due to rapid drying. Adding fresh ink or using a drying retardant can help solve this issue.
3. High ink viscosity. Excessive viscosity can lead to poor ink transfer, causing blockage on the printing plate. Reducing the ink's viscosity can help resolve this.
Additionally, dust or paper particles in the ink can be transferred to the printing plate, leading to plugging. This is especially common in environments with poor cleanliness.
Solution: Install a 120-mesh filter in the ink inlet tube to trap foreign particles. Maintaining ink viscosity around 9 seconds is ideal for good print quality and color density.
Second, Mismatch Between Printing Plate and Anilox Roller
A common issue occurs when the printing plate and anilox roller are not properly matched. For example, using a 300-mesh anilox roller with an 80-line pattern can cause excessive ink transfer, leading to over-inking and plugged dots.
Solution: The standard ratio should be around 1:4.5 to ensure proper ink distribution and prevent over-inking.
Third, Operator Errors
Improper operation, such as applying too much pressure, can cause the printing plate to deform, leading to enlarged dots and eventual plugging. The recommended gap between the printing pressure and the cardboard thickness is approximately -0.3 mm.
Solution: Proper training for operators is essential to avoid excessive pressure and maintain consistent print quality.
By addressing these factors—ink formulation, equipment matching, and operator training—printers can significantly reduce the occurrence of plug-in issues, improve efficiency, and meet the high standards required by major clients.
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