Even the most advanced printing factory occasionally face printing defects, with misregistration being a common challenge. Despite the skill of the press operators, achieving perfect prints depends on the precise alignment between ink combinations and substrates. Even the slightest misalignment can disrupt color patterns and design accuracy.
Resolving misregistration issues can be difficult, so we consulted our image carrier experts for their top tips. They provided four effective solutions for tackling misregistered prints.
Common Causes of Print Misregistration in Flexographic Printing
As detailed in our previous discussion on the "10 Common Causes of Print Misregistration in Flexographic Printing," the primary causes include:
Inaccurate plate mounting/centering
Impression cylinder concentricity
Cylinder/plate/sleeve condition
Gear condition
Idle rollers dragging or rotating irregularly
Malfunctioning web guide
Web growth or fanning out
Wandering web
Substrate surface tension
Incorrect tolerances
While identifying the exact cause of misregistration can be complex, it’s essential to pinpoint what’s misaligned and why. Our experts focus on three main areas: across the web, around the web, and mounting cameras.
Identifying and Resolving Misregistration Issues
Across the Web Misregistration
Misregistration often occurs across the web when plates align but sleeves do not. Start by checking if the sleeve is correctly mounted to the mandrel. If everything appears in order, a malfunctioning web guide might be the culprit, with internal sensor errors causing false signals.
These errors typically involve the sleeve, meaning plates might align correctly, but misregistration will still occur around the web (discussed below) with the image carrier.
Around the Web Misregistration
For around the web misregistration, correct gearing is crucial. Running a sleeve with incorrect gear diameters can significantly disrupt print alignment. Additionally, check the condition and wear of your gears, as even a single misaligned, broken, or bent gear can cause severe print defects.
Compromised gears lead to a gradual decline in print quality, emphasizing the need for regular maintenance and checks.
Misregistration by Mounting Cameras
Flexo printing machine operators understand the critical role of mounting cameras. Although cameras may seem secure, they can be accidentally bumped or moved. Regularly checking camera alignment ensures they remain accurate, preventing misregistration.
Partner with Experts to Minimize Misregistration Issues
Identifying the cause of misregistration is just the beginning. Fixing the issue can be daunting due to the many possible press locations where misregistration can occur. Consulting with your image carrier expert helps preserve plates and sleeves while minimizing press downtime.
Don’t Tackle Misregistration Alone
Addressing misregistration requires expertise to avoid costly shutdowns, press damage, or operator injury. Partnering with experts is essential to reducing these risks and maintaining high-quality prints.
