In gravure printing, it's common for operators in flexible packaging factories to report abnormal issues without providing detailed descriptions. For instance, when an ink shortage occurs, the problem might be described vaguely, but the underlying causes can vary significantly, and so do the solutions. Therefore, it's essential to understand the specific reasons behind ink shortages and how to address them effectively.
1. **Ink shortage due to low ink levels in the ink tank** – This is one of the most frequent issues. The possible causes include: first, the ink pump may stop supplying ink due to a malfunction; second, the ink tank might shift or move, causing the ink level to drop; third, the ink level might be too low if the production speed increases rapidly. To resolve this, first, check and repair the ink pump to ensure proper ink flow. Second, stabilize the ink tank to prevent it from moving again. Third, adjust the ink level according to the production speed to maintain consistency.
2. **Ink shortage caused by dents on the impression cylinder** – This issue often happens when there are pits on the magenta impression cylinder or bumps on the printing plate. The solution involves increasing the pressure on the impression cylinder. If the problem persists, the cylinder may need to be replaced. Alternatively, reducing the production speed and adjusting the pressure can help. If the issue still remains, the printing plate should be replaced.
3. **Improper ink level in the ink tank leading to ink shortage** – This occurs when the ink tank is set too high during preparation, causing deposits at the bottom to touch the printing plate and scrape parts of the image. Additionally, if the scraper blade is too long and the ink tank is too high, the paper may curl and intermittently touch the plate. To fix this, lower the ink level so that the printing plate is submerged between 1–37.5 mm. Also, stop the machine and trim the back side of the blade to prevent curling.
4. **Missing edges on text or patterns** – This can happen if the printing plate dots are clogged and not cleaned before starting the machine. Using the wrong ink or solvent, or having incorrect ink viscosity, can also cause this issue. The solution includes cleaning the plate with a solvent-dipped cloth and decontamination powder before starting. If necessary, use a washing solution to ensure all dots are clear. Replace the ink or solvent if they are inappropriate. Regularly check the ink viscosity and keep it within the normal range to avoid unwanted air currents around the press.
5. **Ink shortage caused by water droplets or oil stains** – This can occur when the humidifier produces excessive moisture, leading to water droplets falling on the printing plate. A leaking cooling water pipe can also result in water contact with the plate. Additionally, if the cooling water temperature is too low, condensation may form and damage the print. To prevent this, ensure the humidifier is properly adjusted, check for leaks in the cooling system, and regulate the temperature to minimize condensation.
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