Analysis of troubleshooting examples of rubber rollers together during printing

Printing issues caused by material quality problems are quite common, especially when it comes to critical components like the rubber roller in a printing press. These parts play a crucial role in determining print quality. I recently encountered two issues related to faulty rubber rollers during the printing process, and I’d like to share my troubleshooting experience and tips on how to properly use these components. During one production run, the cyan color started off fine but gradually became lighter. To investigate, I first stopped the ink flow on the printing plate and used the standard method of checking pressure—by pressing the roller against the plate surface. The ink mark width was about 9 mm, which indicated excessive pressure. After adjusting it back to normal, the machine was restarted, but then we noticed a "paste" phenomenon at the edge of the plate. The plate surface was heavily contaminated, and the water supply fluctuated between too much and too little. Next, I checked for water droplets on the plate and blanket tips, which led me to adjust the pressure of the metering and water rollers. Once everything was set correctly, the water supply stabilized. However, later on, we found that the pressure on the plate water roller had increased again. The adjustment nut wasn’t loose, but after jogging the machine several times, the pressure varied each time. This inconsistency suggested an underlying mechanical issue. After removing all the water rollers, we examined the rubber rollers and found their surfaces were flat with no signs of wear. We then removed the bearings from both ends and discovered that the sleeves on the rubber rollers were eccentric. This meant that when the water roller was installed, the pressure at different points around the circumference varied significantly. If the pressure was adjusted based on the thicker part of the rubber, the thinner areas would have less pressure, leading to ink buildup and poor water control. Alternatively, if the pressure was set based on the thin area, it would be too high elsewhere, causing the ink to fade over time. Replacing the faulty rubber roller with a new, high-quality one resolved the issue. The root cause was clearly the poor quality of the original rubber roller. Both the materials department and the printing workshop failed to properly inspect the component before installation, which led to the problem. This case highlights the importance of carefully selecting and maintaining printing components. Even small defects can lead to significant operational issues. Always ensure that critical parts like rubber rollers are thoroughly checked before use. The above content is selected from the journal “Printing Technology · Digital Graphic Arts” of the Science and Technology Media Journal, Issue No.6, 2014. For more information, please visit the journal channel. Welcome to download the iPad version of “Keyin Journal.”

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