What are the most common printing failures and how can they be avoided?
Thermal printing failures can be caused by various reasons. As each item in the process has different specifications, each ribbon needs to be at the right speed and temperature to ensure correct operation. Furthermore, both have to be configured to work together.
To explain this better we have listed some of the most common causes of print failures. Check it out!
Print failures: understand the causes and how to avoid them
There are many causes for print failures, as you will see below. But first of all, like other devices, the easiest way to avoid problems is to carry out preventive maintenance of the equipment.
Now, check out the main causes for print failures or printer errors.
Compatibility issues between the ribbon and the base (label).A lack of compatibility between these two elements can result in some problems. Such as:
- lack of image sharpness: the image is blurry when it comes out of the printer
- coverage failure: greyish or porous looking image
- no print at all: the label comes out white
To avoid these situations, it is recommended that you always test the printer, matching the ribbon to compatible labels. This will allow you to check whether this is the cause of the print failure. Another potential cause of issues is a change in the composition of the transfer ribbon or the label used.
Surface tension, corona treatment and varnishes
Also regarding compatibility between parts, each ribbon requires a minimum surface tension so that it can fix the ink onto the base. Materials such as BOPP, for example, do not have this characteristic and therefore receive a special treatment (Corona, Topcoating) or a layer of varnish.
However, over time these treatments lose their effect. At this point, print faults will occur due to the label material and not the transfer ribbon.
The ribbon is wrinkling, tearing or slipping
This basically occurs when the ribbon is installed incorrectly in the printer. However, if the ribbon is fitted correctly, there are other causes for you to consider. For example, the rewind tension may be too low.
Also, if the print temperature is too high, this can cause wrinkling and even ribbon breakage. When this happens, the film supporting the pigment melts. This may be due to the presence of dirt on the print head.
In addition to temperature, very low speed and excessive pressure on the print head can cause the ribbon to break.
Problems in the image: lack of sharpness, clarity or excess opacity
These problems are generally also linked to the temperature of the print head. If it is too low, this can result in image problems. In addition, a high print speed and excessive pressure on the print head can lead to deformation of the print media.
The image may even come out blurred or leaking over the sides. In these situations, there are two main causes. One is high temperatures, which cause the heat from the print head to distort the printed image, and the other is an excessive print speed, which reduces the contact between the print head and the label.
Printing with “blind spots” or “blind streaks”
If the other print locations are adequate and there are still blind spots, the problem may be in the cleaning of the equipment. This is because, for example, glue from previous labels or other residues can make the print head dirty.
Any residue can accumulate and overheat the head, causing damage and even burning it. When this occurs, it must be replaced. The recommendation is to stop printing immediately and clean the print head.
Problems with sensors
Thermal printers have sensors that detect the labels and the ribbons. When the sensor does not identify them, it may not have been installed correctly. It could also be that the device is dirty or misaligned. So, it is very important to clean and realign it to solve this issue.
In today’s article, we have listed some of the reasons that may be causing your print failures. To continue receiving important information about printing and printer ribbons, keep an eye out on our social media.
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