Flexography Troubleshooting Guide

Adhesion
Bleed
Blushing (Hazing,
Fogging)
Color Too Strong
Color Variations
Among Same Color
Jobs Being Run In A
Plant
Dirty Printing
Flexography
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Excessive Ink
Consumption

Fill-in of Reverses
and Type
Float on Ink
Foaming
Ghosting
Halo Around Print
Kick-out
Mottle
Pinholes or
Fisheyes

Screening
Set-off and/or Blocking
Settling of Ink
Sheet Feeding Problem
Smearing
Striations
Tracking
Trapping
Weak Color

Flexography Troubleshooting Guide

Adhesion
Problem: Ink flakes off substrate, comes off when crinkled, or is
removed easily in tape test.
Cause:
1. Viscosity too high
2. Viscosity too low
3. Ink surface tension too high
4. Incorrect ink system for substrate
5. Poor film treatment
6. Ink drying too slow

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7. Substrate surface contamination

8. Insufficient web temperature

Solution:
1. Reduce viscosity consistent with acceptable
printability
2. Add virgin ink to fountain
3. Consult your technical sales representative
4. Ensure that the correct ink for the substrate
is being used
5. Check surface of film for adequate treatment;
treat in-line, if possible
6. Check driers for heat and airflow; consult
your ink manufacturer
Solvent Flexo: Reduce with faster solvent
blend
7. Check with film supplier as to advisability of
applying a primer before printing, use in-line
treater
8. Increase temperature settings of driers,
check drier balance

Flexography Troubleshooting Guide

Bleed
Problem: Color spreads into subsequently applied coating or
adhesive.

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Cause:
1. Improper pigment use in ink
formulation

Solution:
1. Consult your ink manufacturer to
reformulate using resistant pigment

2. Coating or adhesive may be

rewetting the dried ink

2. Consult your ink manufacturer to

reformulate using resistant pigment

Flexography Troubleshooting Guide

Blushing (Hazing, Fogging)
Problem: Milky, foggy or matte appearance in an ink or coating.
Cause:
1. Solvent Flexo: High humidity
causing excess moisture build-up
in ink
2. Solvent Flexo: Moisture
condensation on surface of drying
ink

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Solution:
1. Solvent Flexo: Consult your ink
manufacturer for properly balanced
solvent blend for specific ink and
printing conditions
2. Solvent Flexo: Use less hygroscopic
solvent blend for ink reduction;
coordinate with your ink manufacturer

Flexography Troubleshooting Guide

Color Too Strong
Problem: Visual color different from standard.
Cause:
1. Solvent Flexo: Ink viscosity too high
Water Flexo: Ink pH too high
2. Ink pigmentation too high

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3. Inappropriate anilox roll; cell volume

too great or cell count too low
4. Inadequate pressure setting on
impression roll
5. Plate and/or ink metering roll
durometer too low
6. Inadequate impression on doctor
blade

Solution:
1. Solvent Flexo: Reduce viscosity to proper
level with recommended solvent blend
Water Flexo: Check and adjust pH then
reduce viscosity to proper level
2. Reduce ink colorant strength with balanced
extender
3. Replace anilox roller with one of higher line
count and/or lower volume capacity
4. Adjust impression for optimum printability
5. Consult plate and/or roller manufacturer
6. Adjust doctor blade to recommended
pressure

Flexography Troubleshooting Guide

Color Variations Among Same Color Jobs
Being Run in a Plant
Cause:
1. Poor viscosity control
Water Flexo: Lack of pH control
2. Variation in substrate porosity or
surface treatment
3. Previously used ink
4. Inadequate amount of ink in
fountain or doctor blade chamber
5. Different suppliers of same color
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6. Variation in ink batches

7. Non-standard process design

Solution:
1. Establish set procedures for viscosity
control
Water Flexo: Maintain proper pH
2. Consult with ink and substrate
manufacturers for proper measures to
be taken
3. Replace or add virgin ink
4. Add ink to fountain or ensure adequate
ink pressure into enclosed doctor blade
assembly
5. Run only one suppliers ink on a given
color
6. Consult your ink manufacturer
7. Inks must be modified to matched print
station; recommend match visual
standard on-site

Flexography Troubleshooting Guide

Dirty Printing
Problem: Fuzzy extensions of image into non-image area. Impression
increase or change in plate durometer during run. Recovers when taken off
press; sometimes results in cracks in plate during storage.
Cause:
1. Excess ink being applied to plate
2. Excess impression between plate
and substrate
3. Ink viscosity too high
4. Accumulation of paper dust (lint)
5. Ink drying too fast
6. Water Flexo: Ink pH too low
7. Excessive anilox volume
8. Excess anilox impression
9. Plate swell caused by use of
materials not compatible with
printing plates

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Solution:
1. Adjust anilox/fountain roller impression; adjust doctor
blade pressure
2. Reduce to kiss impression for type and minimize
impression consistent with acceptable printability for
reverses
3. Adjust to lowest viscosity consistent with acceptable
printability
4. Improve housekeeping, vacuum paper dust and filter ink
5. Check air flow at between-deck driers; consult your
technical service representative
Solvent Flexo: Use slower solvent blend to reduce ink
6. Water Flexo: Raise pH as instructed to by ink
manufacturer
7. Use lower volume anilox
8. Back off impression of anilox to plate
9. Confer with plate and ink suppliers

Flexography Troubleshooting Guide

Excessive Ink Consumption
Problem: Too few impressions per pound of ink.
Cause:
1. Ink viscosity too high
2. Ink color acceptable, but stronger
than standard
3. Weak ink
4. Excessive anilox volume
5. 2 Roll: Soft metering roller
6. Excess loss on start up or
shutdown
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Solution:
1. Reduce ink to lowest viscosity
consistent with acceptable printability
2. Use balanced extender to weaken
color to the middle of the acceptable
range
3. Check ink for strength vs. original
standard
4. Finer/shallower anilox
5. Check durometer; extend or reduce ink
6. Additional care in ink handling; can be
due to large amount of ink required for
inking station

Flexography Troubleshooting Guide

Fill-in of Reverses and Type
Problem: Ink bridges across small print and non-printing gaps in
design.
Cause:
1. Excess ink being applied to plate
2. Excess impression between plate
and substrate
3. Ink viscosity too high
4. Accumulation of paper dust (lint)
5. Ink drying too fast

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6. Water Flexo: Ink pH too low

7. Excessive anilox volume

Solution:
1. Adjust anilox/fountain roller impression;
adjust doctor blade pressure
2. Reduce to kiss impression for type
and minimize impression consistent
with acceptable printability for reverses
3. Adjust to lowest viscosity consistent
with acceptable printability
4. Improve housekeeping, vacuum paper
dust and filter ink
5. Check air flow at between-deck driers.
Consult your ink manufacturer
Solvent Flexo: Use slower solvent
blend to reduce ink
6. Water Flexo: Raise pH as instructed
by ink manufacturer
7. Use lower volume anilox

Flexography Troubleshooting Guide

Float on Ink
Problem: Non uniform layer on surface of ink in container may
result in a variety of print defects as container is used.
Cause:
1. Non-compatible additive that is
less dense than ink

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Solution:
1. Mix and keep mixing while using.
Agitation in sump may be required in
severe cases

NOTE: All inks should be mixed before use

as a general practice.

Flexography Troubleshooting Guide

Foaming
Problem: Voids in printing, foam visible in sumps, or ink
overflowing sump.
Cause:
1. Too much air being introduced into
ink
2. Ink level in fountain below pump
intake level
3. Ink falls excessive distance when
recycled into reservoir
4. Ink viscosity too high
5. Improperly formulated ink

6. Water Flexo: Poor cleanup

procedures
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Solution:
1. Check for leaks in hoses and pumps.
Adjust pump speed to reduce agitation
2. Fill fountain with ink well above intake
level
3. Use hose or pipe to eliminate long ink
falls into pan
4. Reduce viscosity to allow any bubbles
to rise and break at surface
5. Consult your ink manufacturer
6. Water Flexo: Ensure that no detergent
from clean-up has contaminated ink

Flexography Troubleshooting Guide

Ghosting
Problem: Part of image not printing; resembles an offset of same
image. (See also Tracking)
Cause:
1. Ink dries too fast for anilox
volume, does not adequately
replenish anilox

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Solution:
1. Slow ink down
Add extender
Use coarser anilox
Reduce press speed

Flexography Troubleshooting Guide

Halo Around Print
Problem: Area just inside of printed image with light or no ink; often
accompanied by dirty printing.
Cause:
1. Improper pressure settings on
impression

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Solution:
1. Adjust to as close to kiss impression
as possible, consistent with acceptable
printability

Flexography Troubleshooting Guide

Kick-out
Problem: Coagulated ink, lumps or particles in ink.
Cause:
1. Solvent Flexo: Incorrect solvent
balance during viscosity reduction

2. Solvent Flexo: High humidity

causing excess moisture build-up
in ink
3. Water Flexo: Drop in pH.

4. Mixing incompatible inks

Flexography
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Solution:
1. Solvent Flexo: Consult with your ink
manufacturer for properly balanced
solvent blend for specific ink and
printing conditions
2. Solvent Flexo: Use less hygroscopic
solvent blend for ink reduction.
Coordinate this with your ink
manufacturer
3. Water Flexo: Adjust pH to proper level
with amine solution. Consult your ink
manufacturer
4. Do not mix inks from different vendors
or water inks with solvent inks

Flexography Troubleshooting Guide

Mottle
Problem: Random light and dark spots. May cause color to
appear dirty.
Cause:
1. Substrate has non-uniform caliper
or absorption characteristics
2. Ink viscosity too low
3. Improper impression. Can be
caused by uneven plates, surface
dirt on plates or dirty impression
cylinder
4. Non-optimal plate selection
5. Contaminated plates
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6. Transparent color

Solution:
1. Try lower durometer plate; try opaque
ink
2. Add fresh ink and maintain proper
viscosity
3. Clean plates and impression cylinder;
adjust impression; check and adjust
plate cushion or mounting materials;
remake plates
4. Consult plate manufacturer
5. Wash plates with appropriate solvent or
replace plate if cannot be cleaned
6. Transparent color does not cause
problem, but increasing opacity of the
color match may mask the problem

Flexography Troubleshooting Guide

Pinholes or Fisheyes
Problem: Tiny round voids in printed image. Sometimes confused
with screening.
Slide 1 of 2
Cause:
1. Ink drying too fast
2. Low or uneven treatment level on
film
3. Excessive foam
4. Solvent Flexo: Contaminated film
surface

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Solution:
1. Check air flow at between-deck driers;
consult your ink manufacturer
2. Check film treatment; re-treat or treat
in-line if possible
3. See FOAMING
4. Solvent Flexo: Check with film
supplier about applying a wash coat
before printing; replace with roll of film
from different lot

NOTE: Pinholes generally pertain to unwetted

substrates. Fisheyes are areas where ink has
pulled back, leaving uninked or light areas.

Flexography Troubleshooting Guide

Pinholes or Fisheyes, continued
Problem: Tiny round voids in printed image. Sometimes confused
with screening.
Slide 2 of 2
Cause:
5. Solvent Flexo: Contamination
from poor clean-up of fountain,
rollers, etc.
6. Solvent Flexo: Excess slip
agent in ink

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7. Solvent Flexo: Incorrect ink for

substrate being printed
8. Water Flexo: Excessive defoamer
in ink
9. Water Flexo: Ink surface tension
too high

Solution:
5. Solvent Flexo: Empty fountain,
properly dispose of contaminated ink,
clean fountain and all rollers properly,
and start job with fresh ink
6. Solvent Flexo: Clean up as described
in number 5 above and start up with ink
from a different lot; consult your ink
manufacturer
7. Solvent Flexo: Consult your ink
manufacturer
8. Water Flexo: Add fresh ink to fountain
or replace all ink in fountain with fresh
ink
9. Water Flexo: Consult your ink
manufacturer for recommendation

Flexography Troubleshooting Guide

Screening
Problem: Small voids printed in image area. Often has very regular
shape consistent with anilox pattern.
Cause:
1. Ink drying too fast on anilox roll

2. Inadequate inking of anilox

(starvation)
3. Similar appearance can be caused
by plates or backing

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Solution:
1. Consult ink manufacturer
Solvent Flexo: Reduce with slower
solvent blend
2. Slow down press, increase ink flow, or
slow return to increase ink level in
fountain
3. Consult ink manufacturer or plate
manufacturer

Flexography Troubleshooting Guide

Set-off and/or Blocking
Problem: Ink transfers from image side to back side of substrate
when unrolled; inability to separate printed sheets or to unroll web.
Cause:
1. Drying too slow
2. Excess pressure in re-wound roll
3. Film substrate treated on both
sides
4. Film substrate heavily plasticized
5. Web too warm when rewound
6. Web rewound with too much
surface moisture
7. Solvent Flexo: Trapped solvent in
printed ink film
8. Water Flexo: Trapped amine in
printed ink film
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Solution:
1. Check driers for heat and air flow; reduce ink viscosity
consistent with acceptable printability; consult your ink
manufacturer
2. Reduce rewind tension
3. Avoid excessive pressure in rewind; apply offset powder
to web prior to rewind; overprint with non-blocking clear
varnish, if necessary
4. Avoid excessive pressure in rewind; apply offset powder
to web prior to rewind; overprint with non-blocking clear
varnish; consult your ink manufacturer for different ink
5. Reduce web temperature by chilling within 10 F of
ambient temperature
6. Avoid over chilling which allows condensation to form
on film surface
7. Solvent Flexo: Check driers for heat and airflow;
consult your ink manufacturer
8. Water Flexo: Check driers for heat and airflow;
consult your ink manufacturer

Flexography Troubleshooting Guide

Settling of Ink
Problem: Thick or particulate material in bottom of sumps, pans
or ink containers.
Cause:
1. Old ink
2. Press return at lower viscosity
3. Improper ink formulation
4. Some specialty inks may settle
due to the high specific gravity of
the pigment.

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Solution:
1. Rotate inventory
2. Mix, then combine with virgin ink prior
to use
3. Consult your ink manufacturer
4. Add agitation to the ink sump

Flexography Troubleshooting Guide

Sheet Feeding Problem
Problem: Slipping in delivery belts causing frequent jams in
subsequent operations or on sheetfed presses.
Cause:
1. Ink build-up on delivery belt
2. Worn belts
3. Mechanical problems

4. Inappropriate ink formulation

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Solution:
1. Clean belts
2. Replace belts
3. Ensure all tensions, pressures and
other mechanical adjustments are
correct
4. Consult your ink manufacturer

Flexography Troubleshooting Guide

Smearing
Problem: Ink smeared into non-image area by surface contact
down-line on the printing press.
Cause:
1. Too much ink
2. Too little drying
3. Rewetting by adhesive or coating
4. Mechanical speed mismatch

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Solution:
1. Use a lower volume anilox, increase
nip pressure (2 roll), lower viscosity
2. Increase dry capacity, slow down
press, use faster reducer
3. Change ink, coating reducer or
formulation
4. Adjust combination of plate, mounting
tape and gearing

Flexography Troubleshooting Guide

Striations
Problem: Lines of weak ink or no ink in direction of print run.
Cause:
1. Ink film too thin due to worn or
plugged anilox roller, high durometer
plate or too-low viscosity
2. Improper pressure setting on
impression cylinder and/or anilox
roller due to uneven plates or
substrate
3. Defects in anilox, plate or fountain
roll
4. Ink too transparent

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Solution:
1. Clean or replace anilox roller; remake
plate; check and adjust pH and
viscosity
2. Adjust impression to as near kiss as
possible.

3. Replace or repair defective component;

investigate cause to avoid recurrence
4. Transparent color does not cause
problem, but increasing opacity of the
color match may mask the problem

Flexography Troubleshooting Guide

Tracking
Problem: Ink appears in area where there is no print.
(See Ghosting)
Cause:
1. Ink film too heavy

2. Ink drying too slow

3. Mechanical problems
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4. Difficult design due to extreme

color coverage, degree of trapping
and/or die cut positioning

Solution:
1. Reduce viscosity consistent with
acceptable color and printability; have
ink reformulated for stronger color to
permit thinner film; adjust to proper
pressure at all roller nips
2. Solvent Flexo: Adjust ink drying speed
with supplier-recommended solvent
blend
Water Flexo: Adjust ink drying speed
based on instructions from supplier
3. Adjust and clean all belt and idler roller
surfaces that are in contact with the
printed substrate
4. Change layout of design and/or consult
your ink manufacturer

Flexography Troubleshooting Guide

Trapping
Problem: Cannot achieve good coverage in areas where more than
one color is applied.
Cause:
1. First-down color drying too slow

2. Subsequent colors drying too fast

3. Improper pressure setting on

impression cylinder
4. Water Flexo: Improper viscosity

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5. Incorrect plate or backing

Solution:
1. Consult your ink manufacturer; check
drier capacity; Solvent Flexo: Use
faster-drying reducing solvent
2. Check air flow in between-color driers.
Consult your ink manufacturer; Solvent
Flexo: Use slower drying reducing
solvent
3. Adjust impression on first- and seconddown inks
4. Water Flexo: In general, each
succeeding color requires slightly
higher viscosity; adjust accordingly
5. Use optimal plate, firmer backing

Flexography Troubleshooting Guide

Weak Color
Problem: Visual color different from standard.
Slide 1 of 2
Cause:
1. Ink viscosity too low
Solvent/Water Flexo:
a. Too much solvent added to cut ink
b. Excess clean-up solvent in system
Water Flexo: pH too low
2. Worn anilox roller
3. Plugged anilox roller

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4. Plate durometer too high

Solution:
1. Replace ink totally or add virgin ink to fountain

2. Consult anilox roller manufacturer to verify;

replace if necessary
3. Use brass bristled brush for chrome rollers;
stainless steel bristled brush for ceramic rollers
Solvent Flexo: Clean with recommended
solvent to remove dry ink from cells
Water Flexo: Clean with brush, hot water
(140 F) and detergent to remove dry ink from
cells
4. Remake plates to proper specifications and
replace
continued

Flexography Troubleshooting Guide

Weak Color, continued
Problem: Visual color different from standard.
Slide 2 of 2
Cause:
5. Improper pressure setting on
impression and/or anilox roller
6. Ink too weak for anilox roller
volume

7. Inadequate ink in fountain or in

doctor blade chamber
8. Solvent Flexo: Dirty plates

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9. Water Flexo: Glazed or dirty

plates
10. Water Flexo: Glazed metering roll

Solution:
5. Re-adjust impression for optimum printability
6. Consult your ink manufacturer to strengthen
ink if at all possible. If this is not possible,
replace anilox roller with one having a deeper
etch
7. Add ink to fountain or ensure adequate ink
pressure into enclosed doctor blade assembly
8. Solvent Flexo: Wash plates with
recommended solvent and, if necessary, a
moderately stiff non-metallic brush
9. Water Flexo: Wash plates with warm water, a
mild detergent and a moderately stiff nonmetallic brush
10. Water Flexo: Wash with warm water, a mild
detergent and a moderately stiff non-metallic
brush