Faint print
Check ink level, nozzle condition, gap, resolution setting, speed and surface colour.
Production support guide · UK
TIJ maintenance &
troubleshooting.
A practical fault-finding guide for faint print, missing lines, poor adhesion, smearing, position drift and incorrect variable codes.
Start with the symptom
Change one variable.
Check the result.
Short answer: most TIJ print faults can be isolated by checking the cartridge and nozzle condition, ink suitability, product-to-head gap, product movement, trigger and encoder signals, message settings and time available for the ink to dry.
Do not change several settings at once. Record the symptom, use a known product sample and make one controlled change before printing again. Follow the printer and cartridge supplier’s approved cleaning and safety instructions.
Reviewed by Oxford Traceability · Updated 25 August 2026
ObserveRecord the exact symptom
IsolateChange one variable
VerifyCheck at production speed
01First-line diagnosis
Fast production checks
Separate ink faults
from line faults.
A missing nozzle pattern suggests a different cause from a complete code moving backwards and forwards on the pack.
First print a controlled test and inspect whether the issue is repeatable. Then check cartridge installation and condition, the product gap, surface cleanliness, sensor position, encoder contact and message settings.
- Confirm the correct cartridge and message are selected
- Inspect cartridge seating and follow the approved nozzle-care method
- Check the printhead gap, alignment and rigid mounting
- Confirm trigger position, product spacing and encoder tracking
Protect the cartridge
Do not touch the nozzle plate or use unapproved solvents or tools. Follow the supplier’s storage, wiping, purging and disposal instructions.
02Preventing repeat failures
Standardise the set-up
Turn the good result
into a controlled setting.
Once the print is correct, record the physical position and the settings that produced it.
Simple controls such as labelled recipes, mounting reference marks, operator checks and approved sample codes reduce variation after cleaning or changeover. Recurring failures should trigger a review of product handling and application suitability.
- Save approved messages and restrict editing where appropriate
- Mark printhead, sensor and guide reference positions
- Keep approved substrate samples and code standards
- Track cartridge batch, storage, usage and recurring fault history
Escalate recurring problems
Repeated adhesion, speed or position faults may show that the ink, product control or technology needs re-evaluation rather than further adjustment.
Symptom-led checks
What the code
is telling you.
These are starting points, not substitutes for the manufacturer’s fault codes or safety instructions.
Missing lines
Inspect the nozzle pattern, cartridge seating, stored condition and approved cleaning procedure.
Smearing
Review ink compatibility, dry time, print location and contact with guides or packs.
Poor adhesion
Confirm the finished substrate, coating, contamination and ink family through a trial.
Position drift
Check product guides, sensor repeatability, mounting, belt slip and encoder contact.
Wrong data
Review recipe selection, date rules, permissions, PLC messages and database mapping.
Application checklist
Record these details
before requesting support.
Clear evidence shortens diagnosis and helps distinguish one-off handling problems from system faults.
Fault symptomPhotographs of good and bad codes plus how often the problem appears
Printer informationController, head, cartridge and software or firmware identification
Message settingsResolution, speed, orientation, delay, date rules and variable-data source
Production conditionsLine speed, product spacing, temperature, humidity, dust and cleaning activity
SubstrateExact finished material, coating, supplier, batch and any recent change
Actions already takenCartridge changes, cleaning, remounting, settings and outcome of each test
Frequently asked
Direct answers
for production teams.
For application-specific advice, call 01865 362785.
How should a TIJ printhead or cartridge be cleaned?+
Use only the printer and cartridge supplier’s approved procedure, materials and personal protective equipment. Avoid touching the nozzle plate or applying unapproved solvent, pressure or tools.
Why is my thermal inkjet code faint?+
Possible causes include low ink, blocked or damaged nozzles, excessive print gap, unsuitable settings, excessive line speed, poor contrast or an ink and substrate mismatch.
Why does the ink wipe off plastic?+
The ink may not suit the polymer, coating or surface treatment, or it may not have enough time to dry. Test a compatible fast-dry ink on the exact finished material under real handling conditions.
Why does the code move position on each product?+
Check product guiding and spacing, sensor repeatability, trigger delay, printhead mounting, conveyor slip and encoder contact. Product movement is often as important as printer settings.
Does a TIJ printer need servicing?+
Routine requirements vary by model. Cartridge-based TIJ can have fewer ink-system service items than circulating technologies, but sensors, mounts, controls, cables, cleaning procedures and production integration still require inspection.