Press Problems

And Terminology

Document Number

2002-10-10

Creo Inc.
3700 Gilmore Way
Burnaby, BC
Canada V5G 4M1
(604) 451-2700

Copyright 2002 Creo Inc. All rights reserved.

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Revision History

Revision Date Author Comments

1.0 Consulting Services
th
2.0 Oct 9 02 Ian Williams Ported original content into Techdoc template,
Added table of contents, added appendix by
Pete Schreiber describing “all colour rain”.

IAN W ILLIAMS CREO PRODUCTS INC. CONFIDENTIAL 2002-10-10

 Press Problems
And Terminology

CONTENTS

Revision History........................................................................................................................ 1

1. Press Problems and Terminology ...................................................................................... 1

1.1 Chemical Ghosting ................................................................................................... 1
1.2 Color Variation......................................................................................................... 1
1.3 Dot Gain ................................................................................................................... 1
1.4 Drying Problems....................................................................................................... 2
1.5 Emulsification .......................................................................................................... 2
1.6 Image Wear .............................................................................................................. 2
1.7 Ink Bleeding ............................................................................................................. 3
1.8 Ink Feedback ............................................................................................................ 3
1.9 Ink Piling .................................................................................................................. 3
1.10 Mechanical Ghosting................................................................................................ 4
1.11 Mottled Print............................................................................................................. 4
1.12 Non-image Wear ...................................................................................................... 5
1.13 Offsetting.................................................................................................................. 5
1.14 Paper Piling .............................................................................................................. 5
1.15 Plate Blinding ........................................................................................................... 5
1.16 Print Patterns ............................................................................................................ 6
1.17 Roller stripping......................................................................................................... 6
1.18 Scumming/ Toning ................................................................................................... 7
1.19 Tinting ...................................................................................................................... 7
1.20 Trapping ................................................................................................................... 7
1.21 Water Streaks ........................................................................................................... 7

2. Appendix............................................................................................................................ 9
2.1 Alcolor Rain ............................................................................................................. 9

IAN W ILLIAMS CREO INC. CONFIDENTIAL 2002-10-10

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1. PRESS PROBLEMS AND TERMINOLOGY

1.1 Chemical Ghosting

Definition: Images or patterns appear on sheet, sometimes as a lack of gloss
Verification: Image from one side of sheet shows up on reverse side
Causes: Print job has tendency to ghost
Poor stock
Sheets backed up too soon
Too much drier in ink

1.2 Color Variation

Definition: Ink density change during press run
Verification: Density of ink changes from sheet to sheet without any press adjustments
Causes: Too much alcohol or substitute being used
Ink/ water balance not stable
Dampening solution mixing system not consistent
Dampening solution foams in the pan
Press register not consistent
Press web tension not consistent
Ink film not transferring consistently through the ink train

1.3 Dot Gain

Definition: Shadow dots plugged, highlights and middletone dots enlarged
Verification: Density of solids in spec, but printed sheets looks darker or fuller than proof
Causes: Excessive impression cylinder pressure
Excessive plate and/or blanket packing
Dampening solution too weak
Glazed dampening rollers
Incorrect ink tack
Emulsified ink
Plates exposed incorrectly

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Incorrect form roller settings

1.4 Drying Problems

Definition: Ink doesn’t dry normally
Verification: Ink drying on press, print marks easily though it feels dry to the touch, ink turns
chalky or flakes off sheet, offsetting in the stack
Causes: Poor adhesion/ compatibility between stock and ink
Ink film too thick
Wrong amount of drier in ink
Dampening solution mix too strong
Dampening solution pH too low
Too much water in ink
Stock too acidic

1.5 Emulsification
Definition: A detrimental change in the ink viscosity and piling i.e. excessive water in ink
Verification: Ink looks wet or shiny, water droplets observed in ink train
Causes: Ink film too thick
Ink and dampening solution not matched properly
Too much water being transferred to plate
Dampening solution mixed too strong
Dampening solution contaminated by blanket / roller wash

1.6 Image Wear

Definition: Sharpening of the plate image
Verification: Fine lines disappear, print loses clarity and detail, print becomes weak and
streaked
Causes: Insufficient ink film
Excessive packing of plate or blanket
Dampening solution too strong
Wash-up solvents incompatible with plate coating
Abrasive ink or paper

IAN W ILLIAMS CREO INC. CONFIDENTIAL 2002-10-10

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Hard rollers
Hard blankets
Exposure of plate incorrect
Form rollers too tight
Press wash-up caused swelled rollers or blanket
Ink incompatible with plate coating
Ink too tacky

1.7 Ink Bleeding

Definition: Pigment dissolves or breaks down in the fountain solution
Verification: Dampening solution turns color of ink pigment
Causes: Ink too low in viscosity
Ink not water resistant enough
Pigment is too hydrophilic
Dampening solution pH too low
Too much fountain solution or alcohol substitute being used
Emulsifier or sensitizing agent is being removed from the stock

1.8 Ink Feedback

Definition: Dampening system accepts ink
Verification: Ink building up on pan or metering roller
Causes: Paper sensitizes rollers to accept ink
Rollers contaminated by blanket/ roller wash
Dampening system rollers glazed
Dampening Solution mixture too weak
Dampening system rollers set too tight

1.9 Ink Piling

Definition: Ink piles or cakes on press
Verification: Plates, blankets or rollers have excessive ink, ink not transferring properly to
sheet
Causes: Ink too short

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Ink not water repellent enough

Too much water and ink being used
Dampening solution mix too weak
Not enough water to plate

1.10 Mechanical Ghosting

Definition: Images/ patterns appear in solids
Verification: Ink density in solids or three-quarter tone screens not uniform, low density
areas match previous image in same ink zone
Causes: Dampening solution mix too strong
Dampening solution too cold
Ink film too thin (pigment too strong)
Roller settings improper
Rollers swelled by blanket/ roller wash
Ink too transparent
Poor layout of sheet
Rollers in ink train not oscillating properly

1.11 Mottled Print

Definition: Printed solid or screen areas are not uniform
Verification: Solids and screens look uneven, pinholes show through paper, press cannot
print to standard densities
Causes: Too much water to plate in unit or previous unit
Dampening solution mix too strong
Excessive pressure between blanket and plate
Inadequate pressure between blanket and plate
Blanket is too hard or glazed
Pigment not evenly distributed in ink
Ink does not transfer consistently
Inks not trapping properly (see Trapping)
Ink emulsified (see Emulsification)
Plate image not adequately ink receptive (see Plate Blinding)

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1.12 Non-image Wear

Definition: Anodized layer on plate wearing off
Verification: Plate becomes sensitive easily, “peppering” effect on secondary start-ups
Causes: Abrasive ink prints back onto blanket of next unit
Dampening solution too weak
Ink takes up water too fast
Abrasive paper or pressroom dust on plate

1.13 Offsetting
Definition: Unwanted adhesion between sheets in a load
Verification: Printed sheets stick together
Causes: Not enough spray powder
Spray powder size too small
Sheets piled too high in delivery
Wax content of ink too low

1.14 Paper Piling

Definition: Paper piles on press
Verification: Plates or blankets have excessive paper build-up, due to the adhesion properties
of the plate and/or ink not transferring properly to sheet
Causes: Not enough water being used
Ink too tacky – picking stock
Poor coating adhesion on stock

1.15 Plate Blinding

Definition: Plate image will not accept ink
Verification: Image visible on plate but will not carry ink
Causes: Plate finisher still on plate
Dampening solution too strong
Excessive or incorrect plate cleaner used
Ink emulsified
Contamination in dampening solution

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Ink film too thin

Ink tack too high
Blanket smashed
Ink drying on rollers
Contaminated ink rollers
Plate or blanket underpacked
Paper piling on plate

1.16 Print Patterns

Definition: Unwanted design showing up on the printed sheet
Verification: Horizontal streaks across the sheet (parallel to the gripper)
Causes: Ink body too short
Ink drying too fast
Ink emulsified on rollers
Roller settings too tight or uneven
Glazed ink forms
Worn cylinder or roller bearings

1.17 Roller stripping

Definition: Rollers not carrying ink properly or evenly
Verification: Rollers are bare of ink in areas, usually on the ends
Causes: Glazed/contaminated rollers
Steel or copperized rollers are desensitized
Ink too viscous or ink body is too short
Ink film too light
Too much water being used on plate
Ink emulsified
Water collecting in ink roller train
Dampening solution mix too strong
Rollers contaminated by deglazer or roller wash

IAN W ILLIAMS CREO INC. CONFIDENTIAL 2002-10-10

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1.18 Scumming/ Toning

Definition: Non-image areas of the plate pick up ink
Verification: Check plates for ink in non-image area, reverses fill in, thickening of images
Causes: Ink too soft
Ink film too thick
Insufficient or incorrect dampening solution mixture
Plate sensitized or contaminated
Ink emulsified
Plate anodized surface has worn off
Contaminated roller in dampening system
Improper form roller settings
Form rollers swelled
Plate curves are incorrect for press and/or inks

1.19 Tinting
Definition: Ink breaks down in the dampening solution and transfers to sheet in small
particles
Verification: Ink particles on plate wash off easily with water
Causes: Dampening solution too strong
Ink or water form rollers set too tight
Ink not water resistant enough

1.20 Trapping
Definition: Ink does not lay or adhere properly to previously printed ink
Verification: Press sheet does not match proof even though ink densities are in spec
Causes: Inks have wrong tack
Ink dries too quickly
Too much ink on first down colors
Dampening solution too weak

1.21 Water Streaks

Definition: Vertical Streaks of light density appearing in the print

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Verification: Inconsistent ink density shows as streaks running down the printed sheet
Causes: Metering roller too hard
Glazed dampening rollers
Damaged or worn chrome rollers
Dampening solution too weak
Dampening solution too warm
Water form roller improperly set

IAN W ILLIAMS CREO INC. CONFIDENTIAL 2002-10-10

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2. APPENDIX

2.1 Alcolor Rain

The following information was captured by Peter Schreiber (DU-PSM for CAM) and Kurt
Shelton (PD-PSS Thermal 1.x), who were involved in troubleshooting a problem at a
customer site, who we have called customer “X” to ensure confidentiality.
Of special interest is the Heidelberg term "Alcolor rain".
This refers to the press artifact that is caused by the "incorrect" setting of the water metering
roller.
In short, the water metering roller picks up water from the reservoir and transfers it to the
Chrome roller, which in turn transfers it to the plate (these rollers are part of the Dampening
unit, refer to figure A.)
Figure A.

The film of water on the roller can be adjusted by increasing/decreasing the pressure between
the pick-up roller and the chrome roller, and has a dramatic effect on the final press sheet.
In our recent testing in house and at a local commercial printer, we were able to duplicate the
artifact that customer “X” was seeing, and greatly reduce it by increasing this roller pressure.
Much of the "Alcolor rain" looks remarkably like thermal banding from the laser. This could
explain why, in some cases, when we tune for FM on press, we see banding on plate, but not
on press. This would indicate that we are masking the press banding by introducing plate
banding.

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It is very difficult to distinguish between banding, plate grain and press artifacts. To test
whether the banding is caused by the press or by the imaging system, it is best to isolate the
plate grain, from the Creo imaging direction, and from the press direction. To do this, a test
plate can be cut out of a larger plate at an angle (other than 90°) so that the plate grain is not
in the press or imaging direction.

Imaging
direction Press
Direction

Be very aware of this when a customer complains of banding on press but not on plate.

IAN W ILLIAMS CREO INC. CONFIDENTIAL 2002-10-10