Troubleshooting TTO Printing: Why Do My Prints Look Too Large or Too Small?
Troubleshooting TTO Printing: Why Do My Prints Look Too Large or Too Small?
At ttoparts.com, we often receive calls about an issue many customers face when dealing with intermittent thermal transfer overprinting (TTO). The problem goes something like this:
“When I print at slower speeds, my print looks perfect. But when I speed up my packaging line, the print either gets extra large or too small, sometimes even cut off. What’s going on?”
This can be a frustrating issue, but one cause is simple: the speed of the film has changed, but the timing of the print has not. Let’s break down how this works and how to resolve it.
Understanding Intermittent Printing
Intermittent printing is a mode where the film stops momentarily to allow the printhead to make its mark before the film moves again. Unlike continuous printing, where the film moves constantly and an encoder adjusts the print speed accordingly, intermittent printing does not automatically account for changes in film speed.
When you speed up your production line, the film moves faster, but if the printer’s settings aren’t adjusted to match this new speed, the print will either stretch and appear too large or shrink and get cut off.
Why Doesn't This Happen in Continuous Printing?
In continuous printing, an encoder is used to detect the speed of the film in real time. As the film speeds up or slows down, the encoder communicates with the printer, adjusting the timing of the print so the image stays consistent regardless of changes in line speed. This means that even if the speed fluctuates, the print comes out as designed.
The Simple Solution: Adjusting the Print Delay
The good news is that you may not need to overhaul your printer or slow down your production line to fix this. The solution lies in adjusting the print delay.
The print delay is essentially the timing between when the print command is sent and when the printhead actually makes its mark. If your prints are appearing too large, try increasing the print delay. If the prints are getting cut off or look too small, try decreasing the print delay.
Fine-tuning this setting should help ensure that the print is aligned with the film movement, regardless of how fast your line is running. With a little adjustment, you’ll get the print you designed, even at high speeds.
Final Thoughts
Understanding the difference between intermittent and continuous printing is key to troubleshooting size distortion issues. If you ever run into trouble, remember to consider the print delay and make adjustments as needed. This is a common issue, but with the right settings, it can be resolved quickly.
If you’re still having trouble or need help finding the perfect TTO printer settings for your specific operation, feel free to reach out to us at ttoparts.com. We’re always here to help you optimize your printing process!
