Question: We're having rub issues with digital postcards. We printed a 40,000 variable print order, and the client complained that the cards did not stand up at all well in the mail system. Help!? 

Answer: First, let’s look at the mail system. It handles billions of pieces extremely fast and quite efficiently at a reasonable cost when compared to other countries. If we want postcards to go through the mail well, usually the 6x9” size does well ...Read More

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Question: Gloss-ghosting is killing us. We had a large job on styrene that gloss-ghosted badly. Needless to say, the cost to reprint was high. How can we fix this in the future?

Answer: Gloss or gas ghosting has been with us for years and has become a fair bit better due to our understanding of the process changes needed so that it does not occur. There are a number of reports published by the paper and ink companies, as well as by PIA/GATF. Many things...Read More

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Question: We have implemented color management recently and have done 20 jobs, with 16 of the 20 being excellent in terms of matching between proof and press sheet. We are disturbed that four of the jobs were very bad to say the least. What could be the problem with these? 

Answer: In reviewing those four jobs, I find two jobs printed on uncoated stock and two were supplied proofs. You need to have curves set up for uncoated as well at coated stock. I am a strong believer in having many cur...Read More

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Question: Scheduling in our plant is a disaster. We have a 75-employee firm, and I have had three schedulers in the last three years. None could keep up with our commercial plant operations. Where can I find the right person?

Answer: You can’t. There is no human alive that can schedule your shop. But there are many computerized scheduling systems that can do a wonderful job. Keep in m...Read More

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Question: I hear a lot about 'Lean Manufacturing.' Where is the best application, and how do I start?

Answer: Lean means different things to different people. Lean begins with a 5S program to clean up the plant. If you are not willing to do this, do not even begin lean. To implement a 5S program is work and, like most programs, it starts at the top. The benefits of running a clean plant are great. Once you have ...Read More

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Question: We have far too many butt rolls of various paper in our warehouse. The web pressmen are not using these rolls first. We currently have about 300+ in stock. Should we just send for recycling?

Answer: This is an issue in many plants today. Recycling should be the last thing you do and not the first. As a general rule, we save all rolls over 4´´ in diameter to use as a start-up roll for another job. The best solution I have seen is to keep all butt rolls at the roll st...Read More

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Issue: Why might we be getting dimples and small imperfections on press UV-coated sheets? We are seeing this on sheets (see enclosed samples) that we coat, as well as on those we sent to a trade UV coater.

Comments: What I saw in your sheets was paper fiber and spray powder as well as some just plain dirt. All of those materials were probably on the sheet prior to coating. Keep in mind that if a sheet is going to be offline UV-coated, it needs to be very clean. This is...Read More

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Question: My pressmen have no sense of urgency, and our makeready times are high. We have purchased the latest presses but have seen no improvement in productivity.

Answer: Productivity in any plant is directly related to the expectations that management sets. The new presses on the market are fantastic in terms of improved productivity—and that goes for any brand of press. This industry is blessed with very good hardware.

Are your expectations for makeready time and...Read More

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Question: The quality of our web signatures didn't look good. We had the press manufacturer in to reset all bearer pressures. We think the press is now printing much better. What do you think (sample signatures enclosed)? 

Answer: These samples show an unusual 'across' the cylinder double dot that is inconsistent from signature to signature. This press is not printing as good as it can, probably because the web guide is not working properly. The net result...Read More

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Question: Why are we getting constant complaints from the bindery on sheets that are not dry and are marking? We are a “rush” shop and most jobs deliver in 24 hours or less. Styrene is a killer.

Answer: Well, you are a normal printer facing the problems of RUSH. I assume you have taken care of the easy cures—you are running IR lamps, you are purchasing a press-ready ink, you are not adding lay compounds or tack reducer. If you have done all of those items, then you need...Read More

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Question: We are having what I feel is a serious in problem. We have tried four ink company’s inks to no avail. I have sent to you some sheets and await your reply. What we see are irregular lines that seem to occur primarily in solids and with heavy builds. This seems to happen after the job comes off press since the pressmen say they never see them when they pull sheets.

Answer: I have seen this problem just a few times. When I examine the sheets with a 30× and a 100...Read More

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Question: My pressmen are complaining of hot spots on our CTP plates. We have anywhere from one to 20 on a plate. Our plate remakes have jumped since we changed to an “improved” plate.

Answer: The issue is not as much with the plate as it is with the CTP unit itself. The unit that you purchased does not have dynamic auto focus. Thus, any piece of dirt throws the plate out of focus to the head. There is not easy, cheap solution for this. The marriage of plate and CTP un...Read More

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