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**How to Prevent "Buckle Rubber" in Printing: Causes and Solutions**
Printing is a complex process, and even small issues can lead to significant problems. One common issue in the printing industry is "buckle rubber," which refers to the accumulation of paper fibers, dust, ink residue, and other impurities on the printing blanket or rubber roller. This can cause problems like overprinting, back sticking, poor drying, and even damage to the rubber itself. If not addressed promptly, it can affect print quality, delay production, and result in costly reprints.
So, what causes "buckle rubber" and how can it be prevented?
1. **Insufficient Pressure**
If the pressure between the printing plate and the rubber blanket is too light, it fails to remove paper fibers and dust effectively. Similarly, low pressure between the rubber blanket and the impression cylinder may leave fine particles behind, leading to buildup on the rubber.
2. **Rough Paper Surface**
Papers with a coarse texture, dust, or powder are more likely to stick to the rubber. This is especially true for low-quality or uncoated papers that shed more during the printing process.
3. **Uneven Gasket or Padding**
If the printing plate or rubber pad is uneven, some areas may collect more paper debris, causing localized buckling on the rubber surface.
4. **High Ink Viscosity**
When ink is too thick, it struggles to release paper fibers and dust, increasing the risk of pulling them off the paper and sticking to the blanket.
5. **Ink Contamination**
Impurities in the ink fountain, such as dust, paper particles, or foreign materials, can transfer to the printing plate through the rollers, contributing to rubber buildup.
6. **Improper Water Distribution**
Uneven water application on the water roller can lead to inconsistent ink transfer, increasing wear on certain areas of the rubber and causing excessive "buckle rubber."
To address these issues, here are some effective solutions:
- **Use High-Quality Paper**
Choose paper with a smooth, consistent surface and minimal dust or fiber shedding.
- **Adjust Press Pressure**
Ensure proper contact pressure between the ink rollers, plate roller, and impression cylinder. Increasing the pressure slightly can help prevent buildup without affecting print quality.
- **Maintain Clean Ink**
Regularly clean the ink fountain and rollers. Stir the ink to avoid sedimentation and ensure a uniform mix.
- **Keep Plates and Blankets Clean**
Ensure the printing plates and rubber blankets are flat, clean, and free from debris.
- **Add Backing Paper to Rubber Pads**
For two-color presses, add 0.09–0.15 mm of backing paper to the first color’s rubber pad, while keeping the second color unchanged. For four-color machines, adjust the first two colors slightly but keep the last two the same. This helps reduce overprint errors by 0.01–0.02 mm.
- **Reduce Ink Viscosity**
Add 3–5% of a reducing agent and 1–3% varnish for general prints. For thick inks, consider adding 2% dusting powder. For gold or silver prints, use 2–3% of an escaping agent to improve flow and reduce buildup.
- **Optimize Water Roller Settings**
Adjust the water roller to minimize dirt buildup and maintain even distribution. For coated paper, reduce the use of retackifiers to ensure better ink adhesion and shine.
By carefully observing the printing process and making adjustments based on the machine's performance, most "buckle rubber" issues can be resolved efficiently. With proper maintenance and attention to detail, you can significantly improve print quality and reduce downtime.