FAQs & Troubleshooting

Non-extended delivery with infrared. Recommendation: #2040-3F

Non-extended delivery combining infrared with some hot air and evacuation: Recommendations: #2040-3

Extended delivery with infrared, hot air and evacuation:
Recommendations: Various – Consult ICP Industrial

Yes and no. If “fit” is a potential problem, we recommend you not coat 70lb stock. For more coating flexibility, utilize 80lb stock. Several variables will improve the distortion of lightweight stocks: type of drying system; formula of coating; and amount of coating applied.

With proper drying equipment (ie, extended delivery, hot air, I/R, exhaust), some customers have been successful.

This is easier to achieve in web offset (heat set) than sheet fed. We manufacture a few heat set formulas that have the look and feel of UV.

Put on more coating, without causing other problems.

Run higher viscosity versions of coatings.

If running high gloss now and correct equipment, apply press varnish underneath the equipment.

Remember, the coating mirrors the substrate.

Yes. The inks will “Burnout” resulting in a faded color. Ink companies can reformulate around this issue. It is best to consult with the ink company and ask for alkaline stable color matches.

Very important. We recommend a very hydrophilic, smooth blanket or a photopolymer plate (DuPont, Grace, BASF).

Yes, contact us for specific coating recommendations. First, your end customer should be able to provide the specific FDA regulation requirements necessary for the job. Having this information ready will expedite the ICP Industrial coating recommendation.

Yes, ICP Industrial has a complete line of Water Based and Hot Melt adhesives ready for you to trial. Ask your ICP Industrial Technical Sales Consultant for details.

The water based or aqueous coating is a fluid and we are concerned with the “flow property” of coatings. This “flow property” (a sort of internal friction resisting flow) is measured as viscosity.

Yes. Viscosity can be critical in successfully running coating. The manufacturer of the coating equipment should give you a general range that works best. However, each formula may run best at differing viscosity levels.

There are several different viscosity cups manufactured. We recommend the Gardco Signature Series or E-Z Flow Zahn cups. A Zahn #3 is normally used, but a #2 can also be used. The #2 Zahn is a smaller opening and is therefore more discriminating.

Water generally is your best and safest bet. Some coatings might cut faster with an isopropyl alcohol and water mixture. Your coatings manufacturer will recommend the best procedure.

ICP Industrial is actively planning on being REACH ready with current exported goods. Please call our corporate office for more information. 630.860.7070

Generally, you sacrifice some gloss for protection. This all depends on the formula and application.

The first thing to do is to refer to the MSDS under section 7 which states the following: WASTE DISPOSAL METHOD: No special method. Dispose in accordance with all applicable federal, state and local regulations regarding the disposal of non-hazardous materials. Local waste agencies can help determine the proper disposal method by reviewing the MSDS and may even be able to incorporate the waste with the other waste already being collected at the printer. The other waste we are referring to are ink and varnish waste. The quantity of coating being disposed of is also important. Small residual material found in an empty container, that if spilled of course, must be contained and collected in a waste drum and the remainder should be flushed immediately with copious amounts of water. Any such intentional disposal should be avoided. Environmental agencies and fire departments monitor waste water and have automatic alarms that trigger when the water systems are spiked with chemicals. Accidents happen, and it is always best to notify the proper authorities when they occur. Water Based coatings fall into a similar category to that of floor waxes. Similar precautions and disposal methods have been used in the past. Failure to properly clean and flush spilled areas will result in a thick undesirable translucent film which is difficult to remove after it has been allowed to dry. This build-up is known to clog drainage pipes resulting in undesirable repair costs. Properly disposing coating with some guidance from local agencies that following local and state regulations is the best way to handle any industrial product. In addition, by contacting these agencies you gain the personal satisfaction of having done the right thing for you, your company and the environment.

Solutions:

Pressroom Heat/Humidity Too High

• Adjust environmental controls in pressroom.
• We recommend 72F and 40% relative humidity.

Equipment Not Functioning At Optimum Settings For Job

• Check performance of drying equipment: hot air knives, exhaust, and IR lamps.

Stock Has A High Moisture Content

• Use stock with a moisture content of 5-6 percent.

Applied Coating Film Is Too Thick Or Heavy

• Apply less coating. Adjust application ratre and/or reduce the viscosity.
• Check stripe between metering and applicating rollers.
• Check coating weight and mileage for proper applied coating thickness.

Heavy Ink Coverage

• Use faster setting ink.
• Use a strong ink, so you need to carry less.
• Remember, a heavy 4-process job dries more slowly than light screen work.
• Check with supplies for faster drying or specialized inks and coatings.

Stock Is Nonporous (high holdout)

• Use fast drying inks and coatings.
• Use ink designed for substrate.
• Check with supplies for more compatible inks and coatings for stock.

Ink Picks Up Water (emulsifies)

• Ensure that ink is not contaminated.
• Use a high solid ink.
• Ensure that coatings and inks are compatible.

Incorrect Coating Used

• If all other causes have been addressed, consult ICP Industrial.

Solutions:

Too Much Pressure Between The Blanket And Impression Rolls

• Reduce pressure between blanket roll and impression roll to kiss pressure. To do this, back off pressure to minimal or no coating, then readjust to a continuous film across the sheet. Adjust coater roll accordingly.

Blanket Is Carrying Too Little Coating

• Increase amount of coating to minimize backtrapping but no enough to create an orange peel effect.
• Increase viscosity, if necessary.
• Reduce pressure between blanket roll and impression roll to kiss pressure. To do this, back off pressure to minimal or no coating, then readjust to a continuous film across the sheet. Adjust coater roll accordingly.
• ICP Industrial recommends that you use a hard smooth blanket. Check with your blanket manufacturer.

Too Much Ink Being Applied At A Print Unit

• Adjust ink sequence.
• Check with ink manufacturer about increasing the ink strength to reduce the thickness of the ink film.
• If possible, apply ink in 2 hits.

Ink Sequencing Is Wrong

• Adjust ink sequence.

Ink Tack Is Wrong

• Check with ink manufacturer.

Ink Type Is Wrong

• Check with ink manufacturer.

Ink Is Picking Up Too Much Water From The Fountain Solution

• Check with ink and fountain solution manufacturers.

Coating Is Not Wetting/Trapping Properly Over The Wet Ink

• Consult ICP Industrial about adjusting the formulation of the coating to increase its wetting properties.

Solutions:

Pump Sucks Air Into Circulation System Because Coating Level In Reservoir Or Coating Pan Is Too Low

• Maintain levels so pump intake is always submerged.

Air Is Sucked Into Recirculation System Through Leaks In Pump Seals Or Piping

• Repair leaks, tighten clamps and fittings, and check hoses for holes.

Pump Is Running Too Fast Or At Too High A Pressure

• Set pump for correct speed and pressure.
• Verify that the pump being used is appropriate. ICP Industrial recommends a diaphragm pump.

Pipe/Hose Ends Too Short – Splashing Occurs On Return To Drum/Container

• Prevent freefall by configuring return loop so that outflow (pipe or hose) is submerged into the drum or container.

Coating Is Too Thick

• Reduce coating viscosity by adding water or raising the temperature. Make sure coating is not full of foam or the viscosity will be inaccurate.

Excessive Foaming Still Appears

• If all other causes have been addressed, consult ICP Industrial.

Solutions:

Too Little Coating Is Being Applied

• Increase amount of coating without causing other problems.
• Increase viscosity of coating while maintaining runnability.
• Use a higher solid formula. Consult ICP Industrial.

Incorrect Coating Used

• Consult ICP Industrial.

Improper Stock Choice

• Use stock with smooth surfaces and high holdout.

Ink And Coating Not Compatible

• Use compatible inks and coatings. Consult coating and ink manufacturers.

Excessive Water In Ink

• Consult the ink manufacturer.

Too Much Ink Being Applied

• Check with ink manufacturer about increasing the ink strength to reduce the thickness of the ink film.

Too Much Spray Powder Being Used

• Use little or no spray powder. Use as small a particle size as possible.

Solutions:

Dried Coating

• Blanket may be dirty. Check blanket after every shut down and clean if necessary.

Incorrect Pressure

• Readjust settings.

Coating Viscosity Too Thick

• Reduce viscosity by adding water.

Incorrect Application Substrate

• Check the following: packing, type of blanket being used, type of photo polymer plate.

Loose Blanket

• Adjust blanket.

Solutions:

Coating Is Not Wetting Or Trapping Over The Wet Inks

• Improve the wetting properties of the aqueous coatings by using a different formula. Consult ICP Industrial.

Coating And Inks Are Not Compatible

• Use inks compatible with coating.

Too Much Ink Being Applied

• Check with ink manufacturer about increasing the ink strength to reduce the thickness of the ink film.
• Apply enough coating to minimize or eliminate the problem, but without causing other problems.

Ink Contains Waxes, Silicones Or Other Additives

• Use inks containing minimal additives.
• Consult the ink manufacturer.

Coating Is Drying Too Quickly

• Reduce IR heat without decreasing the speed of drying in load.
• Increase application of coating.
• Use coating that dries more slowly, if possible. Consult ICP Industrial for recommendations.

Pinholing

• Improve the wetting properties of the aqueous coatings by using a different formula. Consult ICP Industrial.

Pinholing Because Coating Is Foaming

• See section on foaming in this guide.

Solutions:

Lightweight Stock (60-80lb text weight)

• Use stock of a higher grade or higher basis weight.
• Use inks that absorb less water.
• Use coatings that dry more quickly.

Stock Absorbing Too Much Water

• Apply less coating by adjusting application rate and/or reducing viscosity.
• Use inks that absorb less water.
• Use coatings that dry more quickly.

Stock Has Low Moisture Content

• Use stock with a moisture content of 5-6 percent. Low moisture stocks absorb more water.

Too Much Heat Used In Drying

• Adjust IR heat until stock no longer curls.

Incorrect Humidity Levels In Pressroom

• Wrap loads or seal with plastic to keep sheets stable.

Mechanical Distortion From The Printing Process

• Check with your press manufacturer.

Solutions:

Stock Is Too Hard (scratches easily)

• Evaluate stock being used.
• Minimize or eliminate spray powder.
• Check with ink manufacturer for high rub inks.
• Consult ICP Industrial for improved, scratch-resistant coating.

Incorrect Coating Used

• Make sure coating is properly formulated to minimize scratching, scuffing, and marking.

Improper Ink Used

• Check with ink manufacturer for high rub inks.

Problems Appear When Coated Piece Is Rubbed Or Handled During Finishing

• Make sure inks and coatings are dry and fully cured.
• Minimize mechanical handling during finishing.

Solutions:

Ink Contains Pigments That Are pH-Alkaline, pH-Sensitive, Solvent Or Hydrophilic-Sensitive

• Use alkali-resistant, permanent pigments.
• Avoid the following alkali-based pigments: rhodamines, reflex/alkali blues, methyl violets, and barium red lake C (warm red); laked and fluorescent pigments.
• All aqueous coatings are alkaline (pH 8.0 to 9.0). This causes sensitive inks to change shade or bleed as the inks oxidize.

Inks Are Formulated With Salt-Containing Pigments

• Exercise care in using these pigments, including lithol rubines, 2B-reds, bon reds, and lithols. Consult ICP Industrial about the best formulation to use with these inks.

Dye Inks Are Used

• Avoid dye inks. Consult ink manufacturer.

Solutions:

Coating Contains Inert Or Dulling Agents

• Verify with ICP Industrial that coating is formulated for the current use. Remember that satin finish will mark or burnish less than a dull finish.
• Change roller nips and/or roller material. Check with press manufacturer for recommended durometer values.
• Use an engraved roller with a chamber/doctor blade coating for best results. Check with press manufacturer for availability.
• Use a smoother and/or harder blanket. Photopolymer plates can also improve results.

Incorrect Application Of Coating

• Change roller nips and/or roller material. Check with press manufacturer for recommended durometer values.
• Use an engraved roller with a chamber/doctor blade coating for best results. Check with press manufacturer for availability.
• Use a smoother and/or harder blanket. Photopolymer plates can also improve results.

Improper Stock Selection

• Use satin or dull stocks for best results.

Incorrect Coating Used

• Consult ICP Industrial.

Imperfections In Pan Or Applicating Roller

• Check and replace roller, if necessary.

Solutions:

Lack Of Adhesion

• Check Dyne levels (surface tension) of the aqueous primer coating, ink, and substrate (independently and together). The Dyne level for aqueous primer coating needs to be compatible with Dyne levels for ink, substrates and off-line coatings.
• Use the least amount of coating possible to minimize coating weight.

Incorrect Coating Used

• Consult ICP Industrial about the proper aqueous coating primer to be used.

Additives In Ink

• Use inks with little or no additives. For example, silicones or waxes such as PTFE (Teflon), Carnauba, EBS (Ethylene bisstearamide), Fischer-Tropsch (methylene), paraffin, or microcrystalline.