Analysis and solution of water-based ink blocking in screen printing
Date: Jul 10 2023 From: Star Color
Water-based ink blocking, also known as ink build-up or ink clogging, occurs in screen printing when excessive ink accumulates on the screen, leading to poor print quality and potential issues with the printing process. It can be caused by various factors, including ink viscosity, screen tension, and improper printing techniques. Here's an analysis of the problem and some potential solutions:
Analysis of Water-Based Ink Blocking:
1.Ink Viscosity: If the ink viscosity is too high, it can result in excessive ink deposition on the screen, leading to blocking issues. High-viscosity inks tend to have poor flow properties, making it difficult for the ink to pass through the screen mesh properly.
2.Screen Tension: Inadequate screen tension can cause the mesh to sag, leading to contact between the screen and the substrate for a longer duration. This can result in excessive ink transfer and build-up, leading to blocking issues.
3.Ink Volume: Using excessive ink during the printing process can lead to ink build-up and blocking. If too much ink is loaded onto the screen, it can easily get trapped in the mesh and cause clogging.
4.Printing Techniques: Inadequate flood and squeegee strokes can contribute to ink blocking. If the flood stroke is not performed correctly or the squeegee pressure is too high, it can result in an uneven distribution of ink and ink build-up on the screen.
Potential Solutions for Water-Based Ink Blocking:
1.Ink Consistency: Adjust the ink viscosity by adding small amounts of water or a specified ink thinner to achieve the desired flow properties. Consult the ink manufacturer's guidelines for proper ink consistency.
2.Screen Tension: Maintain proper screen tension to ensure an appropriate distance between the screen and the substrate. Regularly check and adjust screen tension using a tension meter to prevent sagging and excessive contact time.
3.Ink Volume Control: Use the appropriate amount of ink for the design and substrate being printed. Avoid overloading the screen with ink. Consider using a controlled ink dispensing system or measuring tools to ensure consistency.
4.Printing Techniques: Train operators in proper printing techniques, including correct flood and squeegee strokes. Use smooth and even strokes, ensuring sufficient ink is pushed through the screen while minimizing excessive pressure.
5.Screen Maintenance: Clean screens regularly during the printing process to remove any ink build-up. This can be done using screen cleaning solutions or pressurized water. Additionally, inspect screens for damages or blocked mesh areas and repair or replace them as needed.
6.Testing and Quality Control: Perform regular print tests and quality control checks to identify any ink blocking issues early on. Adjust the variables mentioned above and monitor the print results to ensure optimal ink transfer and minimize blocking.
Remember, specific solutions may vary depending on the equipment, ink, and substrate being used. It's always recommended to consult the equipment and ink manufacturers for specific guidelines and recommendations tailored to your printing setup.
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