Printing and Graphics
CORDES PORCHER OF P2 HELPS CORRUGATED PRINTERS IDENTIFY AND
SOLVE PRINTING PROBLEMS.
The Printing Process
Paper Dust on 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 May/June 2006
Problem
Name: Paper Dust
Also known as: Dirty Plates
Location on sheet and/or printed
elements: This problem is most
notable in screens from the mid
tones to the highlights. It will also be
prominent in the first printing units or
large screen areas.
Signs and symptoms: The suspect
areas will appear to have lines or
fibers connecting or placed between
the dots.
Description: Paper dust on the plate
is the creation of lines of color
between dots or connecting dots that
have a fibrous/fuzzy appearance.
When examined under magnification,
the lines or blemishes will have a
hairy appearance.This problem is now
more pronounced in the direct print
industry as a result of moving to
thinner ink films and coated sheets.
Cause: The most prominent reason
for this problem is dust in the load or
edge of the sheet. The printing
environment will be a major
contributor to the type and quantity
of dust on the surface of the sheet.
Other contributors are as follows but
are not as influential as the one
previously mentioned.
■ Ink pH and viscosity are off target and the ink has
become tacky. This condition will not allow for the ink to
rewet and remove the dust adhered to the plate. This off
target ink will also help attract dust.
■ Ink has moved too far from original formulation as a
result of too much ink chemistry added to the ink. This
condition will not allow for the ink to rewet and remove
the dust adhered to the plate.
■ Plates may be tacky as a result of poor manufacture or
degradation of the plate surface from chemical reaction to
ink or cleaners.
Collateral effects:
■ Extensive plate cleaning;
■ Ink contamination from fibers;
■ Plugged ink filters;
■ Streaks in print as a result of paper fiber stuck between
the anilox roll and doctor blade.
Diagnostic Process
Evaluation:
Under magnification, a review of the sheet will show inked areas
with a fibrous/hairy appearance. The fibers will have taken the
color of the ink printed in the offending unit.
Tools: Magnifying glass 10X-12X, plate cleaning chemistry
Treatment
General measures:
■ Clean sheets prior to printing to remove fiber or debris.
■ Check and adjust ink to target pH and viscosity.
■ Monitor chemical additions to the ink and ensure they
are in compliance in type and quantity for the ink system
in use.
 Printing and Graphics

PAPER DUST ON
PLATE IS THE
CREATION OF LINES
OF COLOR BETWEEN
DOTS OR
CONNECTING DOTS
THAT HAVE A
FIBROUS/FUZZY
APPEARANCE.

DUST ON A PRINTING PLATE WILL RETAIN ITS FIBROUS APPEARANCE.

■ Clean plate and check for plate tack or stickiness and ensure plate Where to seek help:
compatible chemistry is in use. Press manufacturer — Source of sheet cleaning
■ Replace tacky plates and determine cause of problem. equipment for installation on the printing press.
Chemicals: Ink chemistry to adjust pH and viscosity, plate cleaner Ink manufacturer — Review pH/viscosity, resin
compatible with plate material system and chemistry with the ink supplier.
Extreme measures: Paper supplier — Help the paper supplier
■ Purchase and install sheet cleaning equipment; research a liner problem by providing roll number
■ Reformulate ink; information.
■ Change to another liner, paper manufacturer or corrugator; Plate supplier — Ask the plate supplier for a list
■ Change plate material to one more compatible to the ink chemistry and of chemical conflicts with the plate material
cleaning chemicals; involved.
■ A higher volume of anilox roll may be needed to “wash” the plate with ink.
Unfortunately, this will decrease the quality of the graphics and create In every issue, Cordes Porcher identifies ways to
other problems. diagnose, treat and prevent a specific printing
problem. These are only suggestions and have been
Prevention shown to solve problems in other corrugated plants.
Proactive steps: In the process of fixing a printing problem it is
■ Clean sheets prior to printing; important not to override safety mechanisms or
■ Maintain target pH and viscosity; operate equipment in such a way that you run the
■ Monitor and record chemistry adds to ink; risk of injuring personnel or damaging materials or
■ Review all chemicals that will come in contact with the plate for equipment.

compatibility.

Corrugated Today May/June 2006 13