Chapter 14
Identify Issues. Find Solutions. Keep Printing.
Catch problems early for consistent, high quality prints
Even with the best equipment and supplies, issues can happen. Knowing what to look for and how to fix common problems will help you reduce waste, save time and keep your production running smoothly.
1. Poor adhesion
Common Causes
- Under-curing (ink not fully cured)
- Incorrect temperature or time
- Contaminated garment (oils, detergents, softeners)
- Ink not compatible with fabric
Solutions
- Verify cure temperature and time.
- Check garment for moisture or finishes.
- Use the correct ink for the garment.
- Perform wash and stretch tests.
2. Fibrillation
Common Causes
- Raised garment fibers (common on cotton)
- Too much pressure or ink deposit
- Printing on soft fabrics
- No underbase or improper underbase
Solutions
- Use a roller squeegee to smooth fibers.
- Print a smooth underbase.
- Use proper squeegee durometer, angle and pressure.
- Maintain consistent off-contact and speed.
3. Ink bleeding
Common Causes
- Too much ink deposit
- Excessive pressure or low mesh count
- Ink viscosity too thin
- Printing wet-on-wet without proper control
Solutions
- Reduce ink deposit and pressure.
- Use the correct mesh count.
- Adjust ink viscosity.
- Allow proper flash time between colors.
- Use a sharper stencil and correct squeegee.
4. Dye migration
Image comparison: Without Blocker Ink / With Blocker Ink
Common Causes
- Garment dye moves into the printed ink (especially polyester and some blends)
- High dryer temperatures
- Not using a low-bleed or blocker ink
- Garment not tested for bleed resistance
Solutions
- Use a low-bleed or blocker ink system.
- Follow manufacturer’s cure guidelines.
- Test garments before production.
- Use appropriate mesh and stencil.
5. Pinholes
Common Causes
- Contaminated or improperly cleaned screen
- Dust or debris on mesh or garment
- Ink drying in screen
- Ink viscosity too high
- Damaged emulsion or stencil
Solutions
- Keep screens clean and dust free.
- Maintain proper flood stroke.
- Use the correct ink viscosity.
- Check for damaged mesh or emulsion.
- Keep a controlled environment (temperature and humidity).
6. Ghosting (hot stacking)
Common Causes
- Garments stacked while still hot from the dryer
- Excessive dryer exit temperature
- Too short of a cool-down time
- High pressure from stacking
- Heat-sensitive inks or additives
Solutions
- Allow garments to fully cool before stacking.
- Use proper dryer exit temperature.
- Increase cool-down time (conveyor or racks).
- Avoid tight, heavy stacks.
- Test your ink and garment combination.
Additional Quality Checks
- Inspect prints regularly during the run.
- Check for consistent color, coverage and registration.
- Monitor flash and cure temperatures.
- Perform wash and stretch tests.
- Keep a record of settings that produce good results.
- Address small issues early to prevent larger problems.
Pro Tip
If you see an issue, compare it to a good sample print. Identifying the problem early helps you make quick adjustments, reduce waste and keep production running smoothly. Consistent quality comes from monitoring your process and using the right supplies for each job.