This article is part of the FLEXO FLAW FIXING series

Even the most sophisticated and advanced print shops occasionally encounter print defects. Even the most skilled press shops can be affected by misregistration in flexo printing.

Every press operator strives to produce the best prints possible. This requires precise and accurate alignment of your ink combinations and substrate. Misregistration by even a fraction of an inch can affect everything from color patterns to design accuracy.

Resolving misregistered prints can be a difficult task, and seeking advice from experts in the field can help find solutions. Here are some tips and solutions that image carrier experts have suggested for resolving misregistration issues:

Say Goodbye to Misregistration in Flexo Printing With These 4 Solutions!

Print misregistration is a common issue that can occur during the printing process, which results in misaligned images or text. Here are the ten most common causes of print misregistration:

  1. Paper movement: The paper can move slightly during the printing process, causing the images or text to be misaligned.
  2. Press vibration: Vibrations from the press can cause the paper or plates to shift, resulting in misaligned prints.
  3. Ink density: If the ink density is too high or too low, it can cause the images or text to misalign.
  4. Plate wear: As printing plates age, they can wear down, which can cause misregistration during the printing process.
  5. Plate damage: Plates can be damaged during the printing process, such as scratches or dents, which can cause misalignment.
  6. Plate cylinder or blanket cylinder damage: Damage to the plate cylinder or blanket cylinder can cause misregistration.
  7. Poor quality paper: If the paper is of poor quality or has an inconsistent thickness, it can cause misregistration.
  8. Plate mounting errors: If the plates are not mounted correctly on the plate cylinder, it can cause misalignment.
  9. Improper ink sequence: If the ink sequence is incorrect, it can cause the images or text to be misaligned.
  10. Poor press maintenance: Lack of proper press maintenance can cause various issues, including misregistration.

Addressing misregistration issues can be challenging, even for experienced operators. It’s crucial to determine which element is not registering and the underlying cause of the issue. Typically, experts usually examine three key areas to pinpoint the source of misregistration: misregistration across the web, misregistration around the web, and misregistration caused by mounting cameras.

Discover the Hidden Dangers of Across the Web Misregistration!

Misregistration is a common problem in printing that can occur on the web, causing plates to align properly while the sleeves do not. To address this issue, it is important to check the mounting of the sleeve to the mandrel and ensure that the tension and centering are correct. 

A malfunctioning web guide can also be the culprit, causing false signals that result in misregistration errors. Misregistration errors are mostly due to issues with the sleeve, even when the plates are aligned correctly. 

Misregistration around the web is caused by the image carrier, which can be caused by mounting, wear, and tear, or a dirty surface. Identifying the root cause of misregistration is essential to prevent it from recurring and ensure high-quality prints.

Don’t Let Around the Web Misregistration Ruin Your Printing Quality!

The importance of correct gearing in preventing web misregistration cannot be overstated. Even a small mistake in the gear diameter can significantly affect print alignment. It is recommended to inspect the gears for wear and tear, as one misaligned or broken gear can cause serious defects in prints. 

Damaged gears can result in poor registration, leading to inconsistent prints and low customer satisfaction. Therefore, it is crucial to maintain and replace gears regularly to prevent misregistration issues and ensure consistent high-quality prints.

Avoid Misregistration in Flexo Printing by Mounting Cameras With These Tips!

Flexo press operators are well aware of the significance of camera mounting. While you may believe your cameras will never be touched, bumped, or moved, mistakes are unavoidable, and it’s critical to check their alignment and ensure they haven’t become misaligned.

Identifying the source of your misregistration is only the first step; fixing the problem, on the other hand, can be overwhelming due to the abundance of press locations where misregistration can occur. Consulting an image carrier expert will ensure that your plates and sleeves are preserved while minimizing press downtime.

Conquer Misregistration in Flexo Printing With Expert Help – You Don’t Have to Face It Alone!

Identifying the source of your misregistration is only the first step; fixing the problem, on the other hand, can be overwhelming due to the abundance of press locations where misregistration can occur. Consulting an image carrier expert will ensure that your plates and sleeves are preserved while minimizing press downtime. When it comes to printing defects, consulting experts is critical to avoiding costly shutdowns, press damage, and operator injury.