Increasing Press Speed and Print Consistency

A leading packaging printer in the Northeast was operating well below press specifications and struggling with chronic ink–water balance issues that were reducing output and driving up waste. Applied Chemistries was brought in to pinpoint the root cause of instability and help the customer restore consistent, high-speed performance.

Client Challenge

Identifying the Source of Roller Contamination and Color Drift

The customer’s production team was running at 14,000 sheets per hour, significantly under the press’s rated 17,000 sheets per hour. Across multiple shifts, operators reported:

Ink build-up on rollers and non-image areas
Unstable color and variation during long runs
Frequent washups interrupting production
Higher-than-normal ink and fountain solution consumption
Excessive waste and increased operator troubleshooting time

Together, these issues slowed throughput, increased cost per job, and weakened overall print consistency.

Our Approach

A Three-Phase Diagnostic and Optimization Process

Applied Chemistries deployed a structured, three-phase assessment to uncover the root causes and deliver a chemistry solution tuned to the customer’s real-world conditions. This approach created a stable, predictable print environment that operators could rely on.

On-Press Observation & Sample Collection

We began by observing the press in full production. Our team monitored:

Roller behavior and ink transfer
Plate wetting and non-image cleanliness
Fountain solution activity and stability
Substrate interaction and print characteristics
Operator workflow and press settings

Ink, fountain solution, and substrate samples were collected for controlled laboratory evaluations.

In-Lab Diagnostics & Root-Cause Analysis

Using the collected samples, our lab ran targeted tests to isolate the causes of ink build-up, color drift, and variable performance. This included:

Duke Ink Emulsification Testing to define the stable ink–water window and measure water uptake under press-like conditions
Toning, bleed, and plate-wetting analysis to identify surface-tension issues
Fountain solution pH and conductivity profiling to evaluate fluid stability over the course of long runs

These diagnostics identified the exact chemistry behaviors driving contamination and instability.

Custom Chemistry Formulation & System Optimization

With a clear understanding of the root causes, Applied Chemistries engineered a real-world solution:

Custom chemistry formulation designed specifically for the customer’s press, plate material, and substrate mix
Circulation and dosing system optimization to maintain steady pH and conductivity throughout production
Roller-conditioning and maintenance program to prevent recurring emulsification and ensure consistent startup-to-shutdown performance

Outcome

Restored Stability, Higher Speeds, and Reduced Variability

Implementing optimized chemistry and system improvements delivered immediate gains. The press achieved stable ink–water balance and cleaner non-image areas, enabling longer uninterrupted runs with minimal intervention.

Key Results

Measurable Gains in Speed, Quality, and Cost Savings

Full Press-Speed Recovery 

Press speed increased from 14,000 to 17,000 sheets per hour — a 21.5% productivity gain with stable print quality.

Reduced Consumable Use

Ink and fountain solution usage dropped by 8–10%, lowering cost per run and reducing waste.

Eliminated Roller Build-Up & Color Drift

Consistent ink–water balance eliminated toning, roller contamination, and mid-run color variation.

Longer Uninterrupted Runs

Fewer washups and cleaner startups gave operators longer production windows and improved shift efficiency.

Connect With a Print Chemistry Expert

Have a print chemistry issue that standard solutions can’t fix? Our lab is ready to help.

Troubleshooting & Optimization Services

Trouble with ink, fountain solution, plates, or press consistency? Learn how our diagnostics and custom chemistry programs can restore stability and performance.

Connect With a Print Chemistry Expert

Have a print chemistry issue that standard solutions can’t fix? Our lab is ready to help.