UV CURING TECHNICAL INFORMATION PAGE

Links: Intensity labels, Dyne Testing + Dyne Pens, Radiometers

TROUBLESHOOTING
IntroductionThe following notes are intended to guide those printers who may be
using UV products for the first time. They are meant to supplement the already
extensive knowledge of printing acquired through day to day experience with
conventional inks and varnishes. The problems listed are varied, and though many
hopefully may never be experienced, they have been included to provide a
reasonably comprehensive aid to the printer. They have been arranged in a clear
format to enable easy reference.
PROBLEM POSSIBLE CAUSES SUGGESTED SOLUTIONS
1. Ink is solid in the can or is becoming solid from the bottom of the container
.
(a) Ink storage area is too warm. Relocate inks in a more suitable area.
(b) Interaction between the pigment and vehicle caused by wrong pigment type.
Contact the ink maker.
(c) Ink has passed its useful life. 6-12 months is usually claimed, but can be
much longer than this. Check the date of manufacture. Practice good storage
methods to avoid using new stock before old.
(d) Ink may be crystallized. This may occur due to ink being stored at too low a
temperature.
(e) Ink may be affected by stray light. Replace lids of containers when not in
use. Screen sunlight from pressroom. Most UV systems do not allow high energy
light to escape.
(f) Contamination of ink by metal parts or metal left in contact with ink after
mixing. Ensure brass or copper does not remain in close contact with ink,
varnishes or coating as this may cause hardening.
2. Ink drying on rollers or blankets; tack increases during run. (a) Rollers and
blankets not compatible with ink. Contact suppliers for alternative products.
(b) Stray light in pressroom. Adequately filter direct sunlight and fluorescent
lamps.
(c) Rollers may not have been primed correctly; still removing low viscosity
components from ink, causing tack to rise. Prime rollers when new, and when
replacing several rollers for maintenance purposes.
(d) Inks may be contaminated by products mistakenly added, i.e. conventional
reducer, or extender (tinting medium). Practice good housekeeping to ensure that
all non-UV products are kept off the press and that a separate storage is kept
for UV products.
3. Piling of ink on rollers, blankets and plates. (a) Blankets and/or rollers
may not be suitable for use with UV cured products. Contact suppliers of
appropriate products for suitable alternatives.
(b) Contamination with spray powder on sheets from previous run on another press
.
Dry-run to remove spray, or crush spray. Removal is preferable.
(c) Ink rheology may be poor due to being of light-fast or light-resistant type.
Reduce ink slightly to improve flow, or contact the ink maker.
(d) Setting of dampers, rollers, plates or blankets may be causing poor transfer
.
Check settings of the mentioned items.
(e) Excess water may make the transfer problem worse, causing some
emulsification. Reduce water setting slightly. UV inks, like conventional
solvent-based inks, run better with minimum water.
4. Blankets embossing. (a) Wrong blanket type. Consult with blanket supplier for
compatible type.
(b) Using relief plate to spot coat with UV coating. Consider using blanket
specifically made for UV.Coating is often more aggressive than ink to the
blanket.
5. Picking of paper surface. (a) Paper surface is too weak, or stock may be 'gre
en'
and lack good surface strength. Change to better stock. Contact mill or paper
supplier if stock has been successfully used before.
(b) Ink tack is too high. Reduce the ink with gelled or liquid reducer. PLEASE
NOTE: Too much reducer may retard proper curing.
(c) Water setting is too high, weakening the coating surface. Apply less
dampening water.
(d) Rollers not primed. Prime rollers with appropriate product or reducer.
(e) Wrong blanket type. Replace blanket.
(f) Interstation lamp not curing sufficiently. Check lamp curing; also, press
speed may be too high causing poor cure.
6. Ink is misting. (a) Rollers set incorrectly. Reset rollers.
(b) Too much ink is being carried on the rollers, or if ink is a tint. Reduce
amount of ink on rollers, or, if ink is a tint, strengthen tint.
(c) Ink rheology is poor. Contact ink maker to improve flow characteristics.
7. Ink 'laying-back' in the duct. (a) Ink may be highly pigmented. Stir
frequently or use duct agitator if available.
(b) Ink formulation may be unsuitable. Consult ink maker.
(c) Ink may be too stiff. Use reducer or ink-duct agitators.
8. Halftones 'filling-in'. (a) Too much ink supplied to plate. Reduce amount of
ink on rollers.
(b) Tack too high, preventing good flow. Mix in small quantity of reducer.
(c) Ink is highly pigmented. Reduce ink with liquid or gelled UV reducer.
(d) Ink may be partially cured by 'stray light'. Ensure light is not reflected
from cylinders onto blankets and plates. Screen off all direct ambient light
shining onto the press rollers and cylinders.
9. Ink transferred to impression cylinders on perfecting presses. (a)
Interstation lamp not on or insufficient time allowed to warm-up. Switch lamp on
or allow lamp to complete 'warm-up' cycle before using it.
(b) Press speed is too high for the lamp to effect a good cure. Slow press speed
slightly until curing is satisfactory or fit more powerful lamp if possible. (Th
is
is often not possible due to press specifications).
(c) Lamp may be failing. Replace lamp.
(d) Electrical problems. Consult electrician.
10. Ink is not curing, or sheets are sticking together in the stack. (a) UV
curing unit is not switched on. Switch on unit, check fuses and circuit breakers
.
(b) Curing unit has lost efficiency due to lamps or reflectors being soiled.
Lamps may also have reached the end of their useful life. Clean lamps and
reflectors, if possible. If not possible, change lamps and reflector skins if
fitted.
(c) Ink is conventional solvent-based ink, not UV. Wash-up rollers carefully
using appropriate solvents and change to UV curing inks.
(d) Film weight of ink is too heavy, beyond the capability of the lamps. Run
less ink if possible or use interstation curing if fitted.
(e) Press speed too high for lamps. Use more lamps, or increase the power of
lamps if applicable. Slow the press speed.
(f) Roller contamination, poor wash-up. Re-wash the rollers; flush oily solvent
and dry properly so that no residue remains.
TROUBLESHOOTING GUIDE FOR COATING
PROBLEM POSSIBLE CAUSES SUGGESTED SOLUTIONS
1. Crawling, cissing or rejecting. Wax in ink or wax in water base. Use flow
additivesUse A-R varnish
Use wax-free ink
Use water based sealer
2. Ink bleaches or changes color. Alkaline inks:Rhodamine red
PMS purple
Reflex blue
Check ink type
Check UV varnlsh
Check UV cure
Use water based sealer
Change ink
3. Ink bleeds color (a) Ink uncured. Give 24 hours to dry
(b) Solvent in varnish. Change varnish
4. Low varnish gloss. (a) Ink uncured. Give 24 hours to dry
(b) Solvent in varnish. Change varnish
(c) Low film weight. Check coaterCheck viscosity
(d) Porous stock. Change substrate
5. Varnish flakes off. (a) Ink uncured. Give 24 hours to dry
(b) Bad substrate. Change stock
(c) Substrate was scored before varnishing. Score after UV
6. Varnish appears to scuff. (a) Ink uncured. Give 24 hours to dry
(b) Varnish undercured. Check lamps.Check varnish.
7. Varnish appears to yellow. (a) Substrate. Check stock.Use water based sealer
(b) Varnish undercured. Check lamps.Check varnish.
8. Finish looks like sandpaper. (a) Offset powder. Change grade or quantity used
Use
water based sealer in-line
Crush powder
9. Post cure odor too high. (a) Substrate too porous. Check stock
(b) Varnish undercured. Check lampsCheck varnish
10. Low mileage. (a) Varnish thick. Use thin varnish
(b) Roller problem. Adjust rollers
(c) Porous substrate. Change stock
11. Blocking/sticking in stack (two sided jobs). (a) Varnish undercured. Check
varnishCheck lamps
(b) Solvent in varnish. Use 100% solids varnish
(c) Not using anti-blocking varnish. Use anti-blocking varnish
12. Poor glueability. (a) Not using glueable varnish. Use glueable varnish
(b) Varnish undercured. Check varnishCheck lamps
13. Poor foil stamp properties. (a) Not using a foil-blockable (additive added)
varnish. Use a foil-blockable (additive added) varnish
(b) Varnish undercured. Check varnishCheck lamp
(c) Aging. Stamp freshly cured coating
14. Varnish slow to cure. (a) Not using high speed varnish. Change to high-speed
curing varnish
(b) Lamps old. Check lamp emission with radiometer.
(c) Varnish old. Check expiration date.
[ Back ] [ UV Curing Home ] [ Next ]