Non conformities in printing dated 05/01/2022 Unit 2-Flexibles division

Job Name Customer Date & shift Operator Machine Non conformity Qty Affected Root caused
Sunlight yellow Unilever Kenya 30/12/21 Night Kennedy New Lines Doctor blade
1kg gravure issue
Sunlight Pink Unilever Kenya 30/12/21 Night Kennedy New Off shade 97kg printed Poor shade
1kg gravure matching
Omo Extra fresh Unilever Kenya 30/12/21 Day Kennedy New Blue scum Approx. 120kg Doctor blade
200g gravure printed issue
Sunlight yellow Unilever Kenya 03/01/22 Night Daniel Flexo ink stains back 170kg printed
40g panel

Sunlight yellow Unilever Kenya 04/01/22 Victor Flexo ink stains front 130kg printed
40g Day panel & Misprint
Trouble shooting defects
Scum
How it is recognized Probable Causes Suggested Remedy
Faint inks appears on Non-image 1. Doctor blade not wiping the 1. Adjust doctor blade if possible or change to a new doctor blade.
areas of the printed substrate cylinder clean 2. Filtering/sieving the ink.
2. Different particle size
pigments present in the
Ink

Lines
How it is recognized
Undesired Continuous lines
showing in the printed & un-
printed areas
Probable Causes
1. Scratches on cylinder
2. Damaged doctor blade
3. Particles logged under the
doctor blade
4. Cylinder not uniform or
chroming not even
Suggested Remedy
1. Polish cylinder
2. Replace doctor blade
3. Filter the ink
4. Polish the cylinder

Off Shade
How it is recognized Probable Causes Suggested Remedy
Actual printed color does not match
standard
Dirty Print/Ink stains
How it is recognized
1. Improper viscosity measuring
and/ or
control
2. Wrong color shade matching
3. color inks from different
supplier
4. Variations in ink batches used
in the press
Probable Causes
1.Excessive ink applied to plate
2. Excessive plate and substrate
impression
3. Substrate surface
contamination with foreign
matter/particles
1. Verify established viscosity control standards are in
place and in use. (Viscosity cups; automatic Viscosity control
equipment is calibrated to inks on each job)
2. Refill or add matching ink (recheck viscosity) confirm using draw
down
3. Ensure adequate ink flow, and ink pressure in
enclosed doctor blade chamber
4. Ensure jobs are run with the same supplier’s ink
5. Strict adherence to color shade matching procedure
Suggested Remedy
1. Adjust anilox roller impression and/or doctor blade pressure
2. Reduce “kiss” impression
3. Adjust viscosity to meet job specifications
4. Clean drum & sleeves