How to crack the printing plate breakage

**Case: Bending Machine Fails** When the bending machine malfunctions, the bent plate becomes slightly tilted, leading to misprints on both the front and back sides during printing. Initially, no serious investigation was conducted, and the root cause of the bending issue was not identified. Instead, a temporary fix was used—applying a piece of tape on the inner side of the plate crease to correct the overprinting error. While this solution addressed the alignment problem, it caused the folding angle to shift, making it difficult for the plate to properly attach to the plate cylinder. After printing around ten thousand times, the plate began to crack, resulting in dirt transfer to the printed sheets. At that point, the press had to be stopped for plate replacement; otherwise, the cracks would have worsened, causing more severe issues. The misprinted plates caused by the bending problem are commonly seen in newspaper printing. In addition to the bending issue, there are cases where the curved edition's angle is inaccurate. The latter situation is subtler than the former, as misalignment may not be immediately noticeable. For example, the tip angle might be too sharp or too wide, or the bending angle could shift, making the plate larger and unable to fit snugly against the plate cylinder. These conditions can easily damage the plate. Therefore, if front and back overprinting is detected, or if the plate doesn’t adhere properly to the cylinder after installation, it’s important to check whether the plate bender is faulty and needs adjustment. **Case: Blank Part of the Printing Plate Not Coated with Fountain Solution** During narrow-web web printing, if the paper width is too narrow and the printing plate has blank areas, the dampening liquid nozzles at both ends of the plate are sometimes closed (using spray dampening). As a result, after some time, the machine produces a loud "click." Upon inspection, several blank areas at the ends of the plate were found to be broken. Analysis revealed that although these areas weren't coated with water or ink, the ink was spread across the layout by the ink roller and accumulated thicker without being removed by the paper. Due to high-speed pressure between the rubber roller and the plate cylinder, and the absence of dampening solution to dissipate heat, the temperature at the edges increased, causing the ink to become more viscous and eventually damaging the plate. To prevent such issues, in similar future orders, the dampening nozzles at the blank parts of the plate are now opened, albeit with reduced water flow. This type of order is rare and typically not encountered in newspaper printing. **Case: Incorrect Cutting Size or Position of Blanket Liner** If the size of the blanket pad is incorrect or its installation position shifts, the pad may not align properly with the surface of the blanket cylinder. Some parts might protrude into the mounting groove of the blanket clip, causing the groove to extend beyond the edge. This leads to additional impact on the plate during printing, increasing the likelihood of plate breakage. If a sudden break occurs at the plate mouth or tip, it’s essential to check whether the blanket pad size is appropriate. With advancements in printing machinery and improved cylinder production accuracy, many presses now use higher-hardness plastic film liners directly attached to the blanket cylinder without frequent replacement. Some presses even mount the blanket directly on the cylinder. Whether using paper or plastic liners, controlling the axial cutting width (typically about 20mm wider than the maximum paper width) is crucial before installation. When installing, align the mouthpiece first (for paper liners, apply glue). Secure the gasket to prevent it from sliding during the blanket installation. Once the gasket is tightly pressed against the blanket for one rotation, trim any excess along the mounting groove edge to avoid issues caused by incorrect sizing or improper installation. **Case: Cracking at Plate Positioning Holes** In newspaper printing, cracks often occur at the positioning holes when the plate is mounted or held. If the crack is located at the drag area, the damage is relatively minor. If only a few printed sheets are involved, the crack may not affect the image area, and the print quality remains largely unaffected. In such cases, we often continue printing until the end, which may waste time but avoids delays. However, if the crack occurs at the cornice area, the press must be stopped immediately. Otherwise, the broken part will be impacted by the rubber roller, causing rapid tearing and potentially damaging the rubber roller, blanket, or even causing paper breaks, leading to more serious problems. [Note] China Packaging Information Network is the official website of China Packaging News and China Packaging Industry Magazine. Contact: Gu Yingyi Mobile Phone Please follow our WeChat public platform for more updates. 

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