Thermal Transfer Printing Problems & Quality Improvement

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Thermal Transfer Printing Problems & Quality Improvement

1. Bar Growth

  • Print speed too high – Reduce speed
  • Old or inferior ribbon media – Replace media
  • Use fresh (not older than one year) ribbon; use premium-grade

2. Insufficient Print Contrast Signal (PSC) or Light Image

  • Print head overheats – Reduce print speed and or print energy
  • Faded image – Ribbon and media incompatible
    • Consult supplier for compatible ribbon/media

3. Unable to Sustain Proper Wide/Narrow Ratio

4. Under burn

(not enough ribbon transfer) – Raise energy setting; use a ribbon with higher sensitivity.

5. Over burn

(too much ribbon transfer) – Reduce energy setting; use a ribbon with lower sensitivity.

6. Bars too thick

– Reduce energy setting; improve ribbon/media quality.

7. Streaks or "Dead Spots" in Labels

  • Wrinkled ribbon
    • Printhead misalignment – Realign printhead
    • Guide bar misalignment – Realign guide bar
    • Adjust printhead pressure
    • Reduce print energy
    • Make sure ribbon width is only slightly wider than label media
    • Adjust rewind tension

8. Pits and/or Voids, Inconsistent Image Quality

  • Dirty print head – Clean print head with Isopropyl alcohol or specialty cleaning solution & cleaning card
  • Dust on label media
  • Dots missing or warn on print head – Replace printhead

9. Poor Edge Definition

  • Printing too fast – reduce print speed, consider “picket fence” format
  • Ribbon and media incompatible – Consult supplier for compatible ribbon/media combination.

10. Leading and/or Trailing Edges of Image are Translucent ("Ghosting")

  • Slew rate to print rate is too – Reduce slew rate, one level at a time
  • Print head temperature is too low- Increase print head temperature level (“heat factor”), one level at a time.

Additional Considerations

PROBLEM POSSIBLE CAUSE SOLUTION
RIBBON SLIPPAGE – KEY SYMPTOM = “GHOSTING” IN NO-IMAGE AREAS RIBBON IS MOVING AT A SLOWER RATE THAN MEDIA. COMMON TO GLOSSY LABEL STOCKS ADJUST UNWIND/REWIND TENSION TO 1:1 RATIO, CHANGE LABEL MEDIA
RIBBON OUT SENSOR DOES NOT SHUT DOWN PRINTER DIRTY SENSOR CLEAN SENSOR WITH COMPRESSED AIR IF POSSIBLE
RIBBON BREAKING PRINTHEAD ENERGY IS TOO HIGH REDUCE ENERGY LEVEL
PRINTHEAD PRESSURE IS TOO HIGH ADJUST PRESSURE
PRINTER SET IN DIRECT THERMAL MODE SET TO THERMAL TRANSFER MODE
UNWIND TENSION IS TOO HIGH REDUCE TENSION
POOR BACK COAT CHECK WITH SUPPLIER/REPLACE RIBBON
PRINTER WILL NOT CALIBRATE DIE CUT LABELS DIRTY SENSOR CLEAN SENSOR
PRINTER SET IN CONTINUOUS MODE SET TO DIE CUT MODE
LABEL LENGTH UNDER MINIMUM FOR PRINTER MODEL ATTEMPT 2 UP FORMAT
SENSOR OUT OF ALIGNMENT ADJUST SENSOR

If you have any queries or would like some help with any technical or sales related issues, feel free to contact us directly.

 

Email: sales@omnimetric.com

Facebook page: https://www.facebook.com/omnimetrictechnologies.official

WhatsApp: +6011-11316698

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