Common Quality Problems in Carton Printing and Their Solutions

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Cartons serve as the outer packaging for various products and play a crucial role in attracting consumers. Therefore, the printing quality of cartons must be strictly controlled. This article outlines several common issues encountered in carton printing, along with their corresponding solutions.

1. Quality Issues Caused by Poor Performance of Embossing Components
When key components such as the shaft heads of the printing plate roller, impression roller, transmission shaft, and gears are worn or loose, they may cause the rollers to jump or slide during the embossing process. This instability leads to uneven pressure, resulting in blurred or unclear printed images or text. To resolve this, a detailed inspection and analysis should be conducted to identify the exact source of the fault. Worn or loose components should be repaired or replaced to eliminate the issue.

2. Quality Issues Caused by Improper Adjustment of Pressure Rollers
If the pressure roller is positioned too high or too low, it may apply excessive or insufficient pressure on the corrugated cardboard, leading to dirty or blurred prints. The pressure roller should be adjusted to an optimal position, ensuring that the gap between the roller and the plate corresponds to the thickness of the cardboard. This adjustment helps maintain consistent printing quality and prevents such defects.

3. Quality Issues Caused by Faulty Ink Rollers
Loose shaft heads, bent or deformed roller bodies, or surface damage on the ink roller can cause dirty, blurred, or unclear prints. The root cause should be identified and addressed promptly. Ensuring uniform and appropriate contact between the ink roller and the printing plate is essential. Damaged ink rollers should be replaced to restore printing quality.

4. Quality Issues Caused by Uneven Thickness of Corrugated Cardboard
Artificial indentations on the surface of corrugated cardboard can lead to unclear printing in those areas. Increasing the overall printing pressure to compensate may cause blurring of text and lines. To prevent this, cardboard should be handled with care during stacking and transportation. Stacking height should be controlled, and improper handling practices such as throwing, smashing, or pressing should be strictly avoided.

5. Quality Issues Caused by Uneven Printing Plate Thickness
Variations in the thickness of rubber plates can result in uneven pressure distribution. Higher areas may cause blurring, while lower areas may lead to incomplete ink coverage. To address this, a segmented plate-making method can be adopted, using smaller plate pieces made from the same material. If thickness differences exist in the existing plate, additional adhesive tape can be applied to the thinner areas to achieve uniform thickness and ensure consistent pressure and ink application.

6. Quality Issues Caused by Improper Color Sequence
Printing large, densely inked graphics in the first color group may result in smudging or dirty prints in subsequent color groups due to slow drying. To prevent this, smaller plates should be printed first, followed by larger plates in subsequent groups. This sequencing helps avoid ink transfer and maintains print clarity.