Poor Adhesion

Ink can be scratched, peeled, or removed by tape after printing.

SOLUTION:

Check substrate surface tension before printing.

Use corona-treated or properly pre-treated films where required.

Ensure the ink is fully cured with correct UV lamp power and exposure.

Reduce ink film thickness by using the correct anilox volume.

Check if the substrate requires primer or special adhesion-promoted ink.

Avoid contamination from silicone, oil, dust, or cleaning residue.

Tacky Surface / Poor Cure

Printed ink remains sticky even after UV exposure.

SOLUTION:

Check UV lamp power, lamp age, reflector cleanliness, and conveyor speed.

Reduce machine speed if UV dose is insufficient.

Reduce excessive ink deposit from the anilox.

Stir ink properly before use.

Check whether the ink is suitable for mercury UV, LED UV, or the installed curing system.

Avoid over-dilution or addition of non-approved materials.

Pinholes / White Spots

Small unprinted dots appear in solid areas.

SOLUTION:

Check anilox cleanliness and cell condition.

Increase ink transfer if the ink film is too low.

Check viscosity and avoid excessive foam.

Use defoamer only if approved and at recommended dosage.

Check substrate surface treatment and cleanliness.

Filter ink if contamination is suspected.

Dirty Print / Filled Text

Fine text, barcode, or halftone areas become filled or unclear.

SOLUTION:

Reduce printing pressure between plate and substrate.

Check pressure between plate and anilox.

Use lower anilox volume for fine work.

Reduce ink viscosity if too high.

Clean the plate and anilox regularly.

Check doctor blade setting and blade wear.

Color Variation During Run

Printed shade changes during production.

SOLUTION:

Keep ink mixed and homogeneous.

Control viscosity and temperature during production.

Check anilox wear or blockage.

Avoid adding excessive reducer or additive.

Maintain constant press speed and UV curing conditions.

Compare print density with approved standard sample.

Anilox Blocking

Ink dries or builds up inside anilox cells, reducing transfer.

SOLUTION:

Clean anilox with approved cleaner.

Do not allow ink to remain idle on the press for long periods.

Check UV light exposure near ink station.

Use correct cleaner for UV ink deposits.

Filter contaminated ink before reuse.

Maintain proper wash-up schedule.

Foaming in Ink Tray

Foam appears in the ink pan and causes uneven print.

SOLUTION:

Reduce excessive pump circulation or air intake.

Check return line position.

Use approved anti-foam only in small controlled quantity.

Avoid contamination with unsuitable cleaners or water.

Check ink viscosity and agitation speed.

Poor Ink Transfer

Ink does not transfer evenly from plate/blanket to container or substrate.

SOLUTION:

Check roller settings and ink film distribution.

Ensure ink is not too stiff or too cold.

Allow ink to reach pressroom temperature before printing.

Use proper ink tack for the job.

Check blanket condition and pressure setting.

Ensure substrate/container surface is clean and suitable.

Piling on Plate or Blanket

Ink builds up on image areas, causing rough print and loss of detail.

SOLUTION:

Clean blanket and plate regularly.

Check ink film thickness and reduce excessive feed.

Check substrate surface for dust, powder, or contamination.

Use suitable ink strength to avoid overfeeding.

Check curing condition and inter-station contamination.

Consult technical team if pigment or resin balance requires adjustment.

Slurring / Blurred Image

Print appears stretched, doubled, or unclear.

SOLUTION:

Check blanket pressure and machine registration.

Reduce excessive impression pressure.

Check plate and blanket mounting.

Ensure the container/substrate is stable during printing.

Use correct ink body and tack.

Check mechanical wear in gears or cylinders.

Poor Cure on Containers

Ink remains soft, tacky, or fails rub test.

SOLUTION:

Check UV lamp output and reflector condition.

Reduce press speed to increase UV exposure.

Check ink film thickness and reduce over-inking.

Make sure container color and opacity are not blocking UV penetration.

Verify whether the ink is suitable for the installed UV system.

Avoid adding reducers or additives beyond approved limits.

Poor Rub Resistance

Printed surface scratches easily after curing.

SOLUTION:

Ensure complete UV cure before testing.

Check adhesion to container surface.

Use proper topcoat or varnish if required.

Avoid excessive ink film thickness.

Check compatibility between ink and container material.

Allow printed items to cool before stacking or handling.

Set-Off / Blocking

Printed containers stick together or transfer ink to each other.

SOLUTION:

Improve UV curing.

Reduce ink film thickness.

Avoid stacking hot containers immediately after curing.

Check conveyor speed and cooling.

Use suitable ink/varnish system for high-speed dry offset.

Inspect storage conditions, pressure, and temperature.

Poor Ink-Water Balance

Ink becomes unstable, emulsified, or weak on press.

SOLUTION:

Maintain correct fountain solution pH and conductivity.

Avoid excessive water feed.

Check roller settings and dampening system.

Use correct UV offset ink for the press condition.

Do not overuse reducer or tack reducer.

Clean rollers and blankets properly.

Chalking / Weak Ink Film

Pigment appears loose and comes off by rubbing.

SOLUTION:

Check if substrate is too absorbent or unsuitable.

Ensure full UV curing.

Use stronger ink or suitable overprint varnish.

Reduce excessive fountain solution.

Check paper/coating quality.

Consult technical team for ink/substrate matching.

Dot Gain / Muddy Halftones

Halftone dots print larger, causing loss of sharpness.

SOLUTION:

Reduce ink film thickness.

Check plate, blanket, and impression pressure.

Maintain correct ink-water balance.

Use correct ink tack and strength.

Check paper surface and absorption.

Confirm plate screening and prepress settings.

Misting / Flying

Ink mist appears at high press speed.

SOLUTION:

Check roller settings.

Reduce excessive ink feed.

Use ink with suitable tack and body.

Reduce press speed if necessary.

Add approved tack reducer only within recommended limits.

Check room temperature and press condition.

Poor Gloss

Printed image has low shine or dull appearance.

SOLUTION:

Use smoother and better coated substrate.

Reduce excessive fountain solution.

Increase ink film slightly only if print quality allows.

Use gloss varnish or glossy ink series.

Ensure complete UV curing.

Avoid contamination from powder, dust, or cleaning residue.

Poor Rub / Scuff Resistance

Ink looks cured but marks or scratches during handling.

SOLUTION:

Check UV cure using proper rub or tape test.

Reduce fountain solution feed.

Use suitable OP varnish or UV varnish.

Check ink film thickness.

Use correct ink for the substrate.

Allow proper cooling before stacking.

Poor Transfer to Substrate

Ink does not transfer completely or evenly.

SOLUTION:

Check roller pressure and ink distribution.

Use correct ink viscosity and tack for letterpress.

Clean rollers and plate.

Check substrate surface treatment.

Increase ink feed gradually, not excessively.

Use correct plate hardness and impression setting.

Dirty Background / Non-Image Marking

Unwanted ink appears in non-image areas.

SOLUTION:

Reduce excessive impression pressure.

Clean plate surface.

Check ink viscosity and reduce if too heavy.

Inspect rollers for uneven setting.

Avoid over-inking.

Check substrate dust or contamination.

Poor Fine Text Definition

Small text or lines appear thick or unclear.

SOLUTION:

Reduce ink film thickness.

Use correct plate and impression pressure.

Use lower viscosity ink if required.

Check roller setting and plate condition.

Clean plate regularly during long runs.

Avoid using high-volume ink feed for fine work.

Poor Cure

Ink remains soft after UV exposure.

SOLUTION:

Check lamp power, lamp age, and reflector cleanliness.

Reduce speed if required.

Reduce ink film thickness.

Confirm compatibility with LED UV or mercury UV system.

Stir ink before use.

Do not add unapproved reducer.

Poor Adhesion on Film or Foil

Ink scratches or peels from non-absorbent substrate.

SOLUTION:

Check corona treatment and surface tension.

Use primer if required.

Use ink grade suitable for film, foil, or synthetic substrate.

Avoid contamination from slip additives or silicone.

Ensure full UV cure.

Conduct tape test before production approval.

Migration or Odor Concern

Printed material gives unwanted odor or requires food-packaging compliance review.

SOLUTION:

Use only approved low-migration ink system.

Do not mix standard inks with low-migration inks.

Do not add unapproved reducers, driers, varnishes, or cleaners.

Maintain good manufacturing practice during printing.

Store low-migration products separately and clearly labeled.

Confirm compliance with required migration testing and documentation.

Set-Off Migration Risk

Ink transfers from printed side to food-contact side during stacking or rewinding.

SOLUTION:

Ensure complete cure or drying before stacking/rewinding.

Reduce stack pressure and reel tension.

Avoid excessive ink film thickness.

Use suitable low-migration varnish if required.

Control storage temperature and humidity.

Confirm packaging structure and barrier properties.

Contamination During Production

Low-migration job may be contaminated by previous standard ink or cleaner residue.

SOLUTION:

Clean press thoroughly before production.

Use dedicated tools, containers, and ink knives where possible.

Avoid using contaminated leftover ink.

Check cleaning solvent compatibility and residue.

Maintain batch traceability.

Keep production records for ink, varnish, substrate, and additives.

Poor Cure in Low-Migration UV Ink

Ink remains tacky or fails rub test.

SOLUTION:

Check UV dose, lamp condition, and machine speed.

Do not add standard photoinitiator or non-approved additive.

Reduce ink film thickness.

Confirm ink is matched to UV or LED system.

Check substrate color and opacity.

Consult technical team before changing formulation.

Incorrect Claim or Documentation Issue

Customer requests Nestlé grade, food grade, low migration, or compliance certificate.

SOLUTION:

Confirm exact customer specification before production.

Provide TDS, SDS, batch details, and compliance statement where available.

Do not claim direct food contact unless specifically approved.

Use correct wording such as “low migration ink for non-food-contact side of packaging” when applicable.

Confirm migration testing responsibility with converter/customer.

Keep all approved samples and records.

Poor Metallic Effect

Gold, silver, or metallic shade looks dull or weak.

SOLUTION:

Stir ink gently but thoroughly before use.

Use correct anilox/roller setting to transfer enough metallic pigment.

Avoid excessive pressure that flattens or disturbs metallic particles.

Use smooth, well-coated substrate for better reflection.

Avoid over-dilution.

Compare shade with approved wet and cured standard.

Metallic Pigment Settling

Metallic pigment settles at the bottom of the container.

SOLUTION:

Mix properly before and during use.

Use slow, controlled agitation to avoid air bubbles.

Do not leave ink standing for long periods during production.

Close container after use.

Avoid contamination with water or incompatible solvents.

Filter only if recommended, because fine filters may remove metallic particles.

Poor Adhesion

Metallic ink scratches or peels from substrate.

SOLUTION:

Check substrate treatment and cleanliness.

Use primer or adhesion-promoted grade if required.

Ensure complete UV curing.

Avoid excessive metallic ink film thickness.

Check compatibility with varnish or lamination.

Do tape test before full production.

Oxidation / Color Change

Metallic shade changes after printing or storage.

SOLUTION:

Keep containers closed tightly.

Avoid moisture contamination.

Use recommended varnish protection where required.

Check storage temperature and humidity.

Avoid acidic or alkaline contamination.

Use fresh ink for critical metallic jobs.

Poor Overprint Varnish Adhesion

Varnish does not bond well over metallic ink.

SOLUTION:

Ensure metallic ink is fully cured or dry.

Check compatibility between metallic ink and varnish.

Avoid over-curing if it reduces intercoat adhesion.

Use recommended OP varnish.

Reduce excessive metallic ink film thickness.

Run trial before production.

Poor Gloss

Coated surface has low shine.

SOLUTION:

Check varnish film thickness.

Use smoother substrate.

Ensure correct coating roller/anilox selection.

Check UV curing condition.

Avoid contamination from powder, dust, or oil.

Use gloss varnish grade suitable for the substrate.

Orange Peel / Uneven Leveling

Varnish surface looks rough or like orange skin.

SOLUTION:

Check varnish viscosity and temperature.

Reduce excessive coating thickness.

Ensure coating roller pressure is even.

Clean coating unit and rollers.

Use proper leveling additive only if approved.

Check substrate absorption and surface smoothness.

Poor Adhesion

Varnish peels, scratches, or fails tape test.

SOLUTION:

Check surface tension of printed or coated substrate.

Ensure ink underneath is fully cured or properly dry.

Avoid applying varnish over contaminated surface.

Use primer if required.

Check compatibility between ink and varnish.

Do not over-cure the first layer if second-layer adhesion is affected.

Cracking on Folding / Creasing

Varnish cracks when folded or creased.

SOLUTION:

Use flexible varnish grade.

Reduce excessive varnish film thickness.

Check board grain direction and scoring.

Avoid over-curing, which may make film brittle.

Test folding performance before production.

Use suitable varnish for packaging applications.

Blocking / Sticking

Sheets or reels stick together after varnishing.

SOLUTION:

Ensure complete UV curing.

Reduce coating thickness.

Allow heat to dissipate before stacking.

Reduce stack height or reel tension.

Check varnish grade and substrate compatibility.

Avoid storing under high heat or pressure.

Varnish Repelling / Fish Eyes

Small craters or spots appear in varnish film.

SOLUTION:

Check for silicone, oil, grease, powder, or dust contamination.

Clean substrate and coating unit.

Avoid incompatible additives.

Check wetting of varnish on printed surface.

Use suitable primer or wetting additive if approved.

Test compatibility before production.

Cleaner Not Removing Ink Properly

Ink remains on rollers, plates, anilox, or machine parts.

SOLUTION:

Use cleaner suitable for UV ink, solvent ink, or water-based ink as required.

Allow enough contact time before wiping.

Use mechanical cleaning for dried deposits.

For anilox, use recommended anilox cleaner and proper cleaning method.

Do not dilute cleaner unless specified.

Repeat cleaning before ink fully hardens.

Roller Swelling or Damage

Rollers become soft, swollen, cracked, or sticky.

SOLUTION:

Use cleaner compatible with roller material.

Avoid leaving strong cleaner on rollers for too long.

Wipe and dry rollers after cleaning.

Do not mix different cleaners without approval.

Check roller supplier chemical resistance.

Use milder cleaner for daily cleaning and stronger cleaner only when needed.

Residue Causing Poor Printing

After cleaning, ink has poor adhesion, poor cure, or contamination marks.

SOLUTION:

Wipe cleaner residue completely.

Allow parts to dry before restarting press.

Do not allow cleaner to enter ink system.

Use lint-free cloth.

Avoid oily or silicone-containing cleaning materials.

Run a short test before production.

Strong Odor or Unsafe Handling

Cleaner gives strong smell or causes operator discomfort.

SOLUTION:

Use in a well-ventilated area.

Wear gloves and eye protection.

Keep container closed when not in use.

Avoid sparks, flames, and hot surfaces if cleaner is flammable.

Follow SDS instructions.

Store away from heat and direct sunlight.

Cleaner Evaporates Too Quickly

Cleaner dries before removing ink properly.

SOLUTION:

Use slower evaporating cleaner where suitable.

Apply cleaner in smaller sections.

Increase contact time by using soaked cloth.

Clean machine parts before ink becomes fully dried.

Keep container closed to reduce evaporation.

Consult supplier for stronger or slower cleaning grade.

Resin Does Not Cure / Remains Soft

Epoxy remains sticky, rubbery, or liquid after expected curing time.

SOLUTION:

Check mixing ratio of resin and hardener.

Mix thoroughly, scraping sides and bottom of container.

Do not guess ratio by eye; use weight or volume as specified.

Check room temperature and curing temperature.

Avoid adding excessive pigment or filler.

Use fresh material within shelf life.

Bubbles in Epoxy

Air bubbles appear inside or on the surface.

SOLUTION:

Mix slowly to reduce air entrapment.

Let mixed epoxy rest briefly before pouring if system allows.

Warm resin slightly if recommended to reduce viscosity.

Use heat gun carefully to release surface bubbles.

Avoid overheating, which can cause yellowing or defects.

Pour in thin layers where needed.

Yellowing

Clear epoxy becomes yellow over time or during curing.

SOLUTION:

Avoid direct sunlight and UV exposure unless UV-stable grade is used.

Do not overheat during curing.

Use low-yellowing hardener for clear applications.

Store resin and hardener away from heat.

Avoid contamination with wrong additives.

Check pigment and filler compatibility.

Fish Eyes / Craters

Small holes or craters appear on the epoxy surface.

SOLUTION:

Clean surface from oil, wax, silicone, dust, or moisture.

Do not touch prepared surface with bare hands.

Use compatible substrate primer if required.

Avoid contaminated mixing tools.

Check pigment or additive compatibility.

Apply in a clean, dust-free area.

Poor Adhesion

Epoxy peels or separates from the surface.

SOLUTION:

Sand or roughen glossy surfaces before application.

Clean surface properly before pouring/coating.

Remove moisture, oil, grease, and dust.

Use suitable primer for metal, concrete, wood, or plastic.

Check curing temperature.

Avoid applying on weak or loose substrate.

Excessive Heat / Fast Gel

Epoxy becomes hot, smokes, cracks, or cures too fast.

SOLUTION:

Mix smaller batches.

Do not leave large mixed quantity in one container.

Use slow hardener for thick casting.

Pour immediately after mixing.

Control room temperature.

Follow maximum pour thickness recommended for the product.

Cloudy or Milky Finish

Clear epoxy appears hazy.

SOLUTION:

Check moisture contamination.

Avoid applying in high humidity.

Warm materials to room temperature before use.

Use dry pigments and fillers.

Mix thoroughly but avoid excessive air.

Check substrate moisture before coating.

Poor Foaming / Low Expansion

Foam effect is weak or not raised enough.

SOLUTION:

Check curing or heating temperature.

Ensure correct foam pigment dosage.

Mix pigment evenly into the base.

Avoid over-grinding or damaging expandable particles.

Check compatibility with binder or resin system.

Test film thickness because very thin layers may not expand properly.

Over-Foaming

Foam expands too much, becomes rough, or loses shape.

SOLUTION:

Reduce foam pigment dosage.

Lower activation temperature if possible.

Reduce film thickness.

Check oven or dryer temperature uniformity.

Avoid excessive dwell time.

Run step-by-step trial to find optimum expansion.

Uneven Foam Surface

Raised effect is patchy or inconsistent.

SOLUTION:

Improve mixing and dispersion.

Check coating or printing thickness uniformity.

Ensure substrate is flat and clean.

Check dryer temperature distribution.

Avoid contamination with oil, silicone, or dust.

Filter base carefully before adding foam pigment if needed.

Poor Color Strength

Foam pigment color looks weak after expansion.

SOLUTION:

Increase color pigment strength in the base.

Use compatible color concentrates.

Avoid excessive foam expansion that reduces color density.

Check pigment dispersion.

Use white base or suitable background where needed.

Compare sample after full drying/curing, not wet stage.

Cracking After Expansion

Foamed layer cracks or breaks.

SOLUTION:

Use flexible binder or resin system.

Reduce film thickness.

Avoid over-heating.

Check substrate flexibility.

Adjust foam pigment dosage.

Allow proper drying before final heating or curing.

Poor Adhesion of Foam Layer

Foam effect peels or flakes from the substrate.

SOLUTION:

Check substrate treatment and cleanliness.

Use suitable binder for textile, paper, plastic, or coating application.

Avoid excessive pigment loading.

Ensure proper drying before expansion.

Use primer if required.

Test wash, rub, or scratch resistance before production.

Clogging During Printing

Foam pigment blocks screen, nozzle, or application system.

SOLUTION:

Use correct mesh or application method.

Avoid using very fine filters after adding foam pigment.

Do not over-grind foam pigment.

Keep mixture gently stirred.

Clean equipment immediately after use.

Check particle size suitability for the process.