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1. Slow Drying Speed

   Phenomenon: Water-based inks dry slowly, especially in high humidity or low temperatures, causing smudging, sticking, or low production efficiency.
   Reason: Relies on water evaporation, with a drying mechanism different from solvent-based inks.
   Solutions:

• Add drying equipment (e.g., hot air, infrared).

• Control ambient temperature and humidity (ideal temperature: 20–30°C, humidity: 50–70%).

• Add quick-drying additives or reduce ink layer thickness.

1. Poor Adhesion

   Phenomenon: Ink peeling or scratching, especially on non-absorbent materials (e.g., plastics, metals).
   Reasons:

• Untreated material surface (e.g., plastics not corona or flame treated).

• Mismatch between ink formulation and substrate.
  Solutions:

• Pre-treat the substrate (cleaning, sanding, corona treatment).

• Select specialized inks (e.g., adhesion-promoting inks for PP/PE).

• Add crosslinkers to enhance adhesion.

1. Screen Plugging (Mesh Blockage)

   Phenomenon: Mesh holes clog during printing, causing pattern defects.
   Reasons:

• Ink dries too quickly on the screen.

• High ink viscosity or coarse pigment particles.
  Solutions:

• Add retarders or humectants.

• Reduce ink viscosity (appropriate add water or diluent).

• Use high-mesh screens or clean screens frequently.

1. Insufficient Color Saturation

   Phenomenon: Dull colors requiring multiple passes to achieve desired results.
   Reasons:

• Low color concentration in water-based inks.

• Thin ink layers or poor ink absorption by the substrate.
  Solutions:

• Choose inks with high pigment content.

• Increase printing passes or adjust squeegee pressure.

• Apply a primer coat to the substrate (e.g., coating layer).

1. Poor Water/Abrasion Resistance

   Phenomenon: Fading when wet or peeling after friction.
   Reasons:

• Incomplete drying or poor film formation.

• Lack of reinforcing additives (e.g., wear-resistant resins).
  Solutions:

• Ensure full drying before overprinting or post-processing.

• Add crosslinkers or UV-curable resins to improve durability.

1. Blistering Issues

   Phenomenon: Bubbles or pinholes on the printed surface.
   Reasons:

• Air entrapment from rapid ink mixing.

• Excessive printing speed or improper screen-substrate spacing.
  Solutions:

• Add defoamers (control dosage to avoid leveling issues).

• Adjust printing speed and screen tension.

1. Substrate Adaptability Limitations

   Phenomenon: Poor performance on special substrates (e.g., smooth plastics, elastic textiles).
   Solutions:

• Select substrate-specific inks (e.g., elastic inks for textiles).

• Adjust printing parameters (e.g., pressure, mesh count).

1. Poor Storage Stability

   Phenomenon: Ink delamination, caking, or deterioration after storage.
   Reasons:

• Microbial growth (common in water-based systems).

• Improper storage temperature (too high or low).
  Solutions:

• Add preservatives (e.g., isothiazolinone-based).

• Store in sealed containers, avoiding high temperatures or freezing.

1. Difficult Viscosity Control

   
   Phenomenon: Viscosity fluctuations affecting printing consistency.
   Solutions:

• Regularly monitor and adjust viscosity (use a viscosity cup or meter).

• Avoid excessive water dilution to prevent ink performance degradation.

1. Balancing Environmental Friendliness and Cost

   Challenge: Water-based inks are eco-friendly but costly, possibly requiring equipment upgrades (e.g., drying systems).
   Recommendations:

• Consider long-term environmental regulations and brand image.

• Collaborate with suppliers to optimize ink usage and processes.

1. Poor Weather Resistance After Printing

   Phenomenon: Color fading, yellowing, or chalking after outdoor use.
   Reasons:

• Lack of UV-resistant or anti-oxidant components in water-based inks.

• Insufficient weather resistance of pigments (especially organic pigments).
  Solutions:

• Choose inks with weather-resistant resins and pigments (e.g., inorganic pigments or special anti-UV formulations).

• Add UV absorbers or light stabilizers.

• Apply a transparent protective coating (e.g., water-based varnish) after printing.

1. Poor Ink Leveling

   Phenomenon: Uneven ink layers with orange peel texture or ripples after printing.
   Reasons:

• High ink viscosity or insufficient fluidity.

• Poor substrate wettability (e.g., hydrophobic materials).
  Solutions:

• Add leveling agents or wetting agents (e.g., silicone-based additives).
  - appropriate reduce ink viscosity (dilute with water cautiously).

• Ensure the substrate surface is clean and oil-free.

1. Inadequate White Ink Opacity

   Phenomenon: Weak white printing coverage, showing underlying colors (especially on dark substrates).
   Reasons:

• Low titanium dioxide content or poor dispersion.

• Thin ink layer or insufficient printing pressure.
  Solutions:

• Use high-opacity white inks (titanium dioxide content ≥30%).

• Increase printing passes or adopt a "wet-on-wet" process.

• Print a primer coat (e.g., gray undercoat) to enhance coverage.

1. Blooming (Whiting) After Printing

Phenomenon: White misty residues on the ink surface after drying.
Reasons:

• High humidity causing moisture absorption during water evaporation.

• Migration of additives (e.g., defoamers) in the ink.
  Solutions:

• Control printing humidity (avoid >70%).

• Reduce defoamer dosage or switch to more compatible additives.

• Increase drying temperature to accelerate water evaporation.

1. Ink and Post-Processing Process Conflict

   Phenomenon: Failure in die-cutting, heat sealing, or lamination after printing, leading to delamination or cracking.
   Reasons:

• Insufficient ink flexibility (e.g., rigid resin formulations).

• Incomplete drying or curing affecting post-processing adhesion.
  Solutions:

• Select inks with flexible resin systems (e.g., polyurethane-based).

• Ensure thorough ink drying before post-processing.

• Test ink compatibility with adhesives/films.

1. Static Interference

   Phenomenon: Ink splashing, fuzzy edges, or dust adsorption during printing.
   Reasons:

• Synthetic materials (e.g., PET, PP) prone to static electricity.

• Enhanced static accumulation in low-humidity environments.
  Solutions:

• Install static eliminators (e.g., ionizing air bars).

• Maintain ambient humidity above 50%.

• Add antistatic agents to the ink.

1. Unstable pH Value

   Phenomenon: Abnormal viscosity changes during ink storage or use.
   Reasons:

• Water-based inks are sensitive to pH fluctuations (ideal pH 8–9).

• Ammonia volatilization reducing alkalinity.
  Solutions:

• Regularly monitor and adjust pH (use ammonia or pH stabilizers).

• Choose low-volatility amine-based neutralizers.

1. Printing Equipment Corrosion

   Phenomenon: Rust or corrosion on metal screens, squeegees, or other components.
   Reasons:

• Water and weak alkaline components in water-based inks.

• Inadequate equipment cleaning or use of non-corrosion-resistant materials.
  Solutions:

• Use stainless steel or plastic screens/squeegees.

• Thoroughly clean and dry equipment after printing.

• Add corrosion inhibitors to the ink (test compatibility first).

1. Color Variation Between Batches

   Phenomenon: Inconsistent colors between different ink batches.
   Reasons:

• Unstable pigment dispersion processes.

• Variations in substrate ink absorption or environmental conditions.
  Solutions:

• Require suppliers to provide color paste batch consistency reports.

• Conduct proofing and color adjustment before printing.

• Stabilize substrate batches and environmental parameters.

1. Poor Low-Temperature Adaptability

   Phenomenon: Reduced ink fluidity and printing difficulties in winter.
   Reasons:

• Increased ink viscosity and freezing tendency at low temperatures.
  Solutions:

• Store ink at ≥10°C and preheat to 20°C before use.

• Add antifreeze agents (e.g., propylene glycol) to lower the freezing point.

• Raise the printing workshop temperature.