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 during printing. Initially, no serious investigation was conducted, and the root cause of the bending issue was not identified. Instead, a temporary solution was applied by placing a piece of tape on the inner side of the plate crease to correct the overprinting error. While this fixed the alignment problem, it caused the folding angle to shift from its original position, which should have matched the angle of the plate cylinder after mounting. As a result, the plate could not be properly attached to the plate cylinder. After printing around ten thousand times, the plate began to crack, causing dirt to transfer onto the printed sheets. At that point, the machine had to be stopped for plate replacement, otherwise the cracks would continue to grow and lead to more severe issues. The misprinted plates caused by the bending problem often appear in newspaper printing. In addition to the bending of the plate, there are cases where the curved edge's angle is inaccurate. The latter situation is more subtle, as it may not be immediately noticeable like the former. For example, the tip of the plate might be folded too far, or the bending angle might shift later, making the plate larger than it should be. This prevents the plate from fitting tightly against the plate cylinder, increasing the risk of damage. If front-to-back overprinting is found to be inaccurate, or if the plate does not adhere properly to the cylinder after installation, it is important to check whether the plate bender is malfunctioning and consider adjustments. **Case: Blank Part of the Printing Plate Not Coated with Fountain Solution** During narrow-web web printing, when 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 the spray dampening method). After some time, the machine makes a loud "click" sound. Upon inspection, several blank areas at the edges of the plate were found to be broken. Analysis showed that although these areas were not coated with water or ink, the ink was spread across the entire layout by the ink roller and accumulated thicker without being removed by the paper. Since the pressure between the rubber roller and the plate cylinder runs at high speed, and no dampening solution was present to remove the heat, the temperature at the edges increased, causing the ink's viscosity to rise. This led to quick damage to the plate. To prevent this, in similar orders, the dampening liquid nozzles at the blank areas are opened, but only a small amount of water is used. This type of scenario is rare and typically not encountered in newspaper printing. **Case: Incorrect Cutting Size or Position of Blanket Liner** If the size of the blanket liner is incorrect, or if its installation position shifts, the liner may not fit neatly against the surface of the blanket cylinder. Instead, part of it protrudes into the mounting groove of the blanket clip on the roller. This can cause the mounting slot to extend beyond the edge, creating additional impact on the plate during printing, which increases the likelihood of the plate breaking. Therefore, if a sudden break occurs at the plate's mouth or tip, it is necessary to check whether the blanket liner's size is appropriate. With advancements in printing machinery and improved cylinder production accuracy, many presses now use higher-hardness plastic film liners directly on the blanket cylinder, eliminating the need for frequent replacements. Some presses no longer use liners at all, attaching the blanket directly to the cylinder. Whether using paper or plastic liners, the axial cutting width must be controlled—typically about 20mm wider than the maximum paper width. Before installation, align the mouthpiece first (for paper liners, apply glue), secure the gasket to prevent sliding, and press it tightly against the blanket for one rotation before trimming any excess along the edge of the mounting groove. This helps avoid issues caused by incorrect sizes or improper installation. **Case: Cracking at Plate Positioning Holes** In newspaper printing, we often encounter situations where the plate cracks at the positioning hole when mounted or held. If the crack is located at the dragging area, the damage is relatively minor. If the number of printed sheets is low, the rupture may not affect the graphic area, and the print quality may remain largely unaffected. In such cases, we often continue printing until the end, even though it may waste time and delay the process. However, if the crack occurs at the corner, the plate must be stopped immediately. Otherwise, the broken part will be quickly torn by the rubber roller and blanket, potentially damaging them or causing paper breaks, which can lead 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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