Printing and Graphics
CORDES PORCHER OF BOBST GROUP USA INC HELPS CORRUGATED
PRINTERS IDENTIFY PROBLEMS AND OFFERS SOLUTIONS.
The Printing Process
Cordes Porcher is a
technical specialist in high
graphics on corrugated for
Bobst Group USA. He
travels internationally
helping the post-print
industry improve and
understand the printing
process. Porcher has 15
years of teaching
experience, with the last 13
spent in printing. He can
be reached at
888-226-8800 or
973-226-8000 ext. 5270.
To mail him your problems
and samples, send them to
Bobst Group USA Inc.,
146 Harrison Ave.,
Roseland, N.J. 07068
cordes.porcher@bobstgroup.com
12 Corrugated Today July/August 2005
Dry Ink
Problem 5. The wrong combination of paper and volume
of anilox roll.
Name: Dry Ink Collateral effects:
Also known as: Sand Paper, Dirty Print 1. Ink contamination — dried ink is transferred
See also: Shooting Stars
to the next station and mixes with this ink
Location on sheet and/or printed elements:
and changes the color.
The lead edge of the image, and highlights
2. Registration — time may be lost trying to
Signs and symptoms: The lead edge of the print
register an image only to find the edge of the
begins to disappear and has a visible crust of ink.
print trying to be registered is missing as a
The highlights to quarter tone dots have a
result of dried ink.
sandpaper feel to them. The solids will have a
3. Shooting Stars — Particles of dried ink are
layered ink appearance and may be speckled.
transferred to large solids, varnish plates or the
Cause:
die-cutting anvil. These particles are crushed and
The ink is drying too fast.
cause streaks with a solid dot at the lead edge of
1. Viscosity/pH: not at target — pH is too low,
the sheet and a tail pointing to the trailing edge.
viscosity is too high.
2. Air flow: excess
drying capacity.
Inks have not
been adjusted for
the use of vacuum
transfer or drying
systems.
3. The press is
running at too
slow a production
speed for the ink
formulation.
4. Foam in the ink is
causing the ink
film to be too thin
to rewet the ink
DRY INK FLAKE UNDER MAGNIFICATION
on the plate. INSET: DRY INK FLAKE UNDER HIGH MAGNIFICATION

ABOVE: SPECKLED APPEARANCE ALONG LEAD EDGE OF SOLID.
BELOW: LEAD EDGE HIGHLIGHTS DISAPPEARING.
4. Extraordinary amounts of plate cleaning.
5. Color shifts can be expected as a result of lack
of ink and ink contamination.
Diagnostic Process
Evaluation:
Gently glide your fingers over the area in
question. The area will have a gritty or sandpaper
feel to it. Many times, the color will transfer to
your fingertips. Under magnification, piles of ink
or flakes will be seen. Plates will have a scale of
ink in the areas in question.
Tools: Magnifying glass 10X-12X, fingers.
Treatment
General Measures:
1. Adjust pH and viscosity back to target levels.
2. Add defoamer to ink. Use this sparingly. Too
much will lead to fish eyes or blemishes in the
print.
Printing and Graphics
3. Add glycol. Use small amounts as it will
lead to other post-printing problems. This
chemical is a temporary fix. The ink
manufacturer should be consulted
regarding quantity and usage.
4. Increase production speed.
5. Evaluate air flow from vacuum transfer and
dryers.
6. Match the absorbance of the liner to the
volume of the anilox roll.
Chemicals: Reducer, pH adjuster, defoamer,
glycol, plate cleaner
Extreme measures:
1. Develop ink system to work with facility and
production variables.
2. Seasonal inks may be needed to match
environmental conditions in the pressroom.
Prevention
Proactive steps:
Continually monitor inks for pH, viscosity, and
foaming.
Establish the proper ink formulas for the
printing variables prior to starting production.
Where to seek help:
Ink manufacturer — assistance in formulation
and chemicals to adjust inks. The ink
manufacturer will be your greatest source for
help with this problem.
Press manufacturer — information regarding
air flow in press.
Dryer manufacturer — information regarding
operation of system and drying capacities.
Editor’s Note: In every issue, Cordes Porcher will
identify ways to diagnose a specific printing problem
and recommend how to treat and prevent it. These
are only suggestions and have been shown to solve
problems in other corrugated plants. In the process of
fixing a printing problem it is important not to
override safety mechanisms or operate equipment in
such a way that you run the risk of injuring personnel
or damaging materials or equipment.
Corrugated Today July/August 2005 13