Color Shift and Micro Banding in a Fairly New Printer

The most common questions we receive regarding our machines involve the printheads—a critical component that is frequently overlooked.

I recently worked with a customer experiencing color shifts and micro-banding. They initially suspected a computer or software issue, assuming the printheads were fine because the machine was only a month old. However, after reviewing photos of the output, we diagnosed the issue as weakened nozzles on their Epson i3200 heads.

When asked for a nozzle test, the customer was unfamiliar with the process. A nozzle test is a vital diagnostic tool that shows the current state of every channel as it fires onto the film. In this case, over 50% of the nozzles were missing. Because the missing nozzles remained static after several cleaning cycles, we determined they were blocked rather than affected by air in the system. Every person should run a nozzle test multiple times throughout busy runs, definitely every morning at start up and have the staff document it.  Maybe even have a manager sign off on it. The printheads are too expensive and not many owners are going to want to buy printheads after 1 month of ownership.

• We successfully recovered the heads to nearly 100% functionality by using printhead recovery fluid in controlled, four-hour soaking intervals. We advised the customer against overnight soaking, as the fluid is aggressive and can damage internal components. 
  
  This serves as a valuable lesson for anyone working with pigmented inks and piezo inkjet heads.

To maintain optimal performance, please follow these guidelines:

• Run frequent nozzle tests: Perform a test at the start, middle, and end of every shift. If you are new to inkjet printing, I recommend a test before every print run.
• Wet cap your heads: Always wet cap the heads between print runs to keep the nozzles hydrated.
• Monitor health: Don't wait for a problem to occur. Knowing the status of your nozzles at all times is the only way to ensure consistent print quality.
  
  Proper maintenance is the best way to prevent unexpected downtime and ensure the longevity of your machine.

About the Author

Scott Hopper is the Lead Technical Specialist at DTF Tech Gurus and brings more than 25 years of experience in digital printing, printer mechanics, color management, and production workflow optimization. Throughout his career, he has served as a digital printing technician on a wide range of commercial and industrial printing systems, including Reggiani textile printers, HP Indigo digital presses, Kornit direct-to-garment systems, and commercial Direct-to-Film (DTF) production equipment. His extensive hands-on experience troubleshooting, repairing, rebuilding, and optimizing production printers gives him a unique perspective on the technology that drives today's digital printing industry. Scott develops technical articles, maintenance procedures, and educational videos that help print shops improve equipment reliability, reduce downtime, and produce consistent, high-quality output.

At DTF Tech Gurus, the mission is simple: provide honest, technically accurate education without the distraction of a sales pitch. Every article is written to share real-world knowledge, practical troubleshooting techniques, and best practices that help print shops make informed decisions, whether they operate an Imperial DTF system or another commerical DTF Printer.