If you've ever printed a sizable number of things, you are
aware of how challenging the process can be. There are several options, ranging
from lithography to inkjet. However, there are frequent problems that might
occur when using a printing business to create big quantities of commercial
goods despite all of these options.
Let's face it: errors occur and are a necessary part of the
process. However, it's still crucial to comprehend the causes of these problems
and how to avoid them in the future. The most frequent faults committed while
going to press using inkjet and offset technologies will be covered in this
article, along with advice on how to completely prevent them.
We'll also examine issues related to color reproduction and
registration as well as talk about ways you can set up a comprehensive
quality-assurance system for your own commercial printing needs. So grab your
favorite writing utensil and get ready for a crash course in commercial
printing—we've got a lot to cover!
Commercial printing is not without its issues--it's no
wonder that companies seek to minimize the problems created by this form of
printing. Whether you're using an inkjet or offset printer, there are a number
of common issues that can cause problems for professionals, so it's important
to be aware of them and how to address them.
Here are some of the more common commercial printing issues
companies and end-users alike face:
- Fading ink: This occurs when the inks used lose
their luster over time, resulting in dull prints. For inkjet printers, frequent
cleaning will help mitigate this issue; offset printers may need new plates and
roller compounds.
- Blurry images: Inadequately created digital images
or photography can lead to blurry results with both kinds of printing. Inkjet
printers will require color calibration for best results; for offset prints,
use a graphics program to check for blurriness before sending it off for
printing.
- Banding: This is when you get repeatable patterning
or streaking in the background of an image or page. For inkjet printers, using high-quality
paper and higher resolution settings can help; offset printers need to be
cleaned regularly and should also use high quality plates.
By being aware of these common commercial printing issues
and their solutions, you'll be better prepared to tackle any problems that come
up during the print process!
When it comes to commercial printing, there are common issue
areas that you may encounter with inkjet printing. This includes dot gain,
vanishing dots, and banding.
Let's discuss what each of these is, and how they can be
avoided.
Dot Gain: Dot gain usually occurs when the printed
dots become bigger than what is actually set. This happens because each drop of
ink expands as it is absorbed into the substrate. To avoid dot gain, you should
try to select a paper stock with minimal absorption and consider using a paper
with higher opacity to reduce show-through.
Vanishing Dots: Vanishing dots occurs when the dots
of one color merge with the dots of another color during the going to press
process, making them look like one solid color instead of separate dots. To
avoid this issue, always choose an inkjet media that has an anti-setoff coating
or opt for different print modes such as Print Quality and High Quality mode
when necessary.
Banding: Banding is another common issue that arises in
inkjet printing and it manifests in thin lines across your prints. This happens
due to inconsistent ink drops from the printer’s nozzles or intermittent
feeding issues from paper rollers inside your printer. You should try using
Print Quality mode rather than Draft mode if you are getting banding, as this
will help provide better consistency in prints.
There are a few frequent problems that come up with offset
printing. Although it might be challenging to determine the specific cause,
being aware of these possible problems can help you see them early on and solve
them.
Blurry graphics and Text
One of the most frequent problems with offset printing is
fuzziness in the text and visuals. This often happens as a result of dirt
particles on the imprint cylinder or plate. You'll need to use a lubricating
solution and cleaning cloth to wipe your plate or imprint cylinder to resolve
this.
Poor Registration
Poor registration happens when colors don't align in the
same position for each image printed. This can be caused by misaligned
movements in the press due to machine wear, inaccurate paper guides, bad feeds,
etc. To resolve this issue, regularly check all components related to machine
movement accuracy and calibrate accordingly using tools like lasers.
Uneven Ink Coverage
Uneven ink coverage is another issue you may encounter when
using offset printing technology. This occurs when different amounts of ink are
applied onto different parts of an image — for example, too much ink on one
part leading to smudging or bleeding, or not enough ink leading to fading
spots. Uneven coverage can be prevented by making sure that inking rollers are
always evenly loaded with ink, so they transfer an even amount onto each part
of the page being printed.
Print monitoring and management might be difficult, but if
you understand the steps involved, the process will go much more smoothly. Here
are some pointers for tracking and managing prints:
Use QR/Bar codes
You can simply keep track of your items by using QR/barcodes
on them. It may be used as a tool to track production and order various parts,
as well as to assist you to determine when a product leaves or enters a warehouse.
If you need to quickly find anything or check sure everything is going as
planned, this may be extremely useful.
Create a system for Internal Tracking
To keep track of all your various manufacturing processes,
your company needs also to put up an internal tracking system. This makes sure
that nothing is missed and that the pieces are all put in the right sequence.
This approach may also be used for inventory management, preventing any
last-minute surprises.
Streamline Your Procedures
And last (but not the least), automating your print
management and tracking procedures may greatly decrease human mistakes and
boost productivity. Additionally, automation makes it possible to collect data
with greater accuracy, which enhances your ability to manage resources and plan
for the next production runs.
You won't have any trouble keeping track of your print jobs
or ensuring that the printing process is going successfully if you stick to
these easy suggestions.
Color is an important consideration if you want your print
production to have an impact. Color management makes sure that the outcome
appears professional and represents your business properly, whether it's
through vivid brand colors, subtle backdrop gradients, or raised-ink
varnishes. But when it comes to color uniformity and precision, inkjet and
offset technologies can present some challenges.
Let's examine a few of the most prevalent ones:
Color Bleed
This happens when one or more of the colors
"bleeds" into another during printing, making the image look blurry
and out of focus. To solve this problem, you need to ensure that the material
being used has passed a bleed check before going ahead with production—if not,
it needs to be corrected.
Colors that clash
A color disparity may occur if the printer is not correctly
set up or if the printed material is given to various vendors for each step of
production. To ensure that your colors are consistent across all mediums, use
pantone matching systems (pms) and create online profiles for each printer you
use.
Dot Gain & Dot Gain Variation
Dot gain occurs when halftones (the dots of ink used in
commercial printing) absorb more ink than intended during printing. This
results in a printed piece that looks washed out or overexposed. To prevent
this from happening, you need to run calibration tests with each job and choose
paper stocks wisely.
By understanding these common issues and taking steps to
address them beforehand, you can get excellent results from both inkjet and
offset print production processes—ensuring your end product looks great every
time!
Print quality issues can be a major cause of frustration
when it comes to commercial printing. It's important to know what type of print
technology is best for a given job, and how to detect any potential problems
with the print quality before they spiral out of control.
Inkjet Printing
Inkjet production employs droplets of liquid or molten ink
that are sprayed onto a substrate, which produces a high-resolution image with
accurate colors, making this type of technology perfect for small format jobs
like labels, brochures and business cards. Potential issue: incorrect mixing of
the inks can cause hues and saturation levels to be off. Solution: always test
before getting into the full production run.
Offset Printing
Offset production is one of the most popular printing
processes used in the commercial printing industry because it produces larger
runs much more economically than inkjet printers – but it's not without its
problems. Potential issue: poor registration can occur if colors don't match up
exactly where they should be, resulting in an inconsistent or blurry image.
Solution: make sure the machines are calibrated correctly, and check colors
regularly on press sheets to ensure they meet customer specifications.
Commercial printing has come a long way in terms of
efficiency and the quality of the output. However, there are still some issues
that can arise during the process, particularly when it comes to the printing
technologies utilized. Inkjet printing is a viable solution for some issues,
while offset printing is more effective in other instances.
It is important to identify the type of issues that can
occur in order to address them properly. Whether it is smudging in the case of
inkjet printing, or registration and color issues in offset printing, learning
the process and understanding the elements of each technique are key. With a
better understanding of the process and the issues that arise, you can be sure
of the best and most cost-effective way of printing for your project.
Apr 24, 2023 by Adekunle Oludele 337 Views