Printing and Graphics
CORDES PORCHER OF P2 HELPS CORRUGATED PRINTERS IDENTIFY AND
SOLVE PRINTING PROBLEMS.
The Printing Process
Paper Sticking to Plate
Cordes Porcher is a
member of the process
improvement team of P2
(P Squared), Renton,
Wash. P2 serves the
packaging industry
through training,
assessment, coaching,
and implementation of
lean strategies for
sustained profitability.
Porcher has 17 years of
teaching and testing
experience with the last
15 spent in printing. He
travels extensively
assisting the entire
printing industry through
training, testing and
product development. He
can be reached at 908-
448-7912 or e-mail
fcporcher@aol.com
12 Corrugated Today March/April 2006
■ Trash or dust in the load or edge of the sheet.
Problem
■ The liner is not corrugated properly and is separating from
Name: Paper sticking to plate the fluting.
Also known as: ■ Paper formation is poor and the fiber bond is not strong
Picking, Fiber Pick enough.
Location on sheet and/or printed Collateral effects:
elements: This is most notable in ■ Extensive plate cleaning;
solids along the lead edge of the ■ Ink contamination from fibers;
image but it can also be found across ■ Plugged ink filters;
an entire solid area. ■ Streaks in print as a result of paper fiber stuck between
Signs and symptoms: The suspect anilox roll and doctor blade.
areas will be void of ink and have a
PAPER FIBER STUCK TO PLATE
fibrous appearance around the edges.
These fibrous edges will appear to
have been torn.
Description: Paper sticking to the
plate is the physical removal of paper
fiber from the sheet or the adhesion
of paper fiber and debris found loose
in the paper to be printed.These areas
of deformed print will have some of
the following characteristics: torn
edge or fibrous area, the shape of
liner with a straight edge.
Cause:
■ Ink pH and viscosity are off
target and have become tacky.
■ Ink has moved too far from the
original formulation as a result of
too much ink chemistry added to
the ink.
■ Plates may be tacky as a result of
poor manufacture or degradation
of the surface from chemical
reaction to ink or cleaners.
 Printing and Graphics

ABOVE: LINER STUCK TO PLATE

BELOW: MAGNIFICATION

PAPER FIBER APPEARANCE TARGET PRINT

Diagnostic Process
Evaluation:
A review of the sheet will show unprinted areas with a fibrous appearance or
will have the appearance of debris in the paper load.
■ The plate will mirror the pattern seen on the sheet with the paper fiber or
debris adhered to the plate.
■ After cleaning the plate, evaluate the plate for tack or stickiness with your hand.
Tools: Magnifying glass 10X-12X
Treatment
General measures:
■ Check and adjust ink to target pH and viscosity.
■ Monitor chemical additions to the ink to ensure they are in compliance in
type and quantity for the ink system in use.
■ Clean sheets prior to printing to remove fiber or debris.
■ Check paper load for trash and loose liner.
■ Clean plate and check for plate tack or stickiness and ensure plate
compatible chemistry is in use.
■ Replace tacky plates and determine cause of problem.
■ Conduct paper picking test as requested by paper manufacturer.
Chemicals: Ink chemistry to adjust pH and viscosity, plate cleaning chemistry
compatible with plate.
Extreme measures:
■ Reformulate ink.
■ Change to another liner or paper manufacturer.
■ Change plate material to one more compatible to the ink chemistry and
cleaning chemical used in the printing facility.
Prevention
■ Monitor and record chemistry adds to ink.
■ Clean sheets prior to printing.
■ Inspect sheets for debris and fiber.
■ Contact paper manufacturer and ask for paper
test methods.
Where to seek help:
Ink manufacturer — Review pH/viscosity, resin
system and chemistry.
Paper supplier — Help the paper supplier
research a liner problem by providing roll number
information.
Plate supplier — Ask for a list of chemical
conflicts with the plate material involved.
In every issue, Cordes Porcher identifies ways to
diagnose, treat and prevent a specific printing
problem. 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

Proactive steps: equipment.

■ Maintain target pH and viscosity.

Corrugated Today March/April 2006 13