Continuous Inkjet (CIJ) Printers are among the most reliable and widely used batch coding solutions in modern manufacturing. Whether it’s the pharma, FMCG, food & beverage, or packaging industry, CIJ printers are trusted for their speed, versatility, and non-stop performance.
However, like any other industrial machine, CIJ printers can occasionally face performance issues—especially in high-volume production environments. Regular maintenance and understanding common printer issues can help prevent downtime, maintain print quality, and extend the printer's lifespan.
In this blog, we’ll explore the most common CIJ printer problems, their root causes, and practical solutions to keep your coding and marking operations running smoothly.
What Is a CIJ Printer?
A Continuous Inkjet Printer (CIJ) is a high-speed, non-contact printing system that uses charged ink droplets to mark codes on products or packaging materials. CIJ printers are ideal for printing batch numbers, expiry dates, barcodes, QR codes, and logos on a wide range of surfaces, including plastic, metal, glass, paper, and film.
They are designed for 24/7 operation and are the backbone of high-volume production lines in pharmaceutical, FMCG, and industrial sectors.
Common CIJ Printer Problems and Their Solutions
Even the most advanced CIJ printer can face issues due to environmental conditions, ink quality, or improper maintenance. Let’s go through the most frequent ones:
1. Poor Print Quality or Faded Codes
Symptoms:
- Blurred or faint prints
- Missing dots or irregular characters
- Ink not adhering properly to the surface
Possible Causes:
- Incorrect ink viscosity or pressure
- Dirty or clogged nozzle
- Incorrect product distance or alignment
- Moist or oily surface on packaging
Solutions:
- Regularly clean the printhead and nozzle using recommended cleaning solutions.
- Check ink and make-up fluid levels; replace if necessary.
- Maintain optimal product distance (typically 2–10 mm) from the nozzle.
- Ensure surfaces are dry and dust-free before printing..
Tip: Always use genuine inks and solvents from trusted suppliers to maintain print consistency.
2. Ink Leakage Around the Printhead
Symptoms:
- Ink dripping from the nozzle
- Messy prints or frequent cleaning required
Possible Causes:
- Damaged nozzle or O-ring seal
- Overfilled ink tank
- Incorrect pressure setting or vacuum failure
Solutions:
- Check and replace damaged seals or filters.
- Ensure proper pressure settings as per the printer manual.
- Avoid overfilling the ink reservoir.
- Schedule regular preventive maintenance to detect wear early.
3. Printer Not Starting or Frequent Shutdowns
Symptoms:
- The printer doesn’t power up
- Unexpected restarts during operation
Possible Causes:
- Faulty power connection or fuse
- Blocked ink lines or pump failure
- Software error or corrupted system file
Solutions:
- Check all power connections and fuses.
- Flush ink lines and ensure pumps are working properly.
- Restart the printer and perform a system reset if prompted.
- If issues persist, contact the authorized service center.
Tip: Always keep your printer firmware updated for smooth operation.
4. Ink Jet Breakup or Misalignment
Symptoms:
- The ink stream deviates or scatters.
- Print characters appear uneven or distorted.
Possible Causes:
- Misaligned deflection plates
- Incorrect ink viscosity
- Dirty charging electrode or nozzle
Solutions:
- Clean the printhead, nozzle, and electrodes thoroughly.
- Check and adjust ink viscosity within recommended limits.
- Use the printer’s alignment mode to recalibrate the ink stream.
5. Blocked or Clogged Nozzle
Symptoms:
- No ink output
- Inconsistent or missing characters
- Printer alarms for low ink pressure
Possible Causes:
- Dried ink residue at the nozzle tip
- Long idle periods without cleaning
- Low-quality or expired ink
Solutions:
- Perform an automatic cleaning cycle or manual cleaning with the correct solvent.
- Always clean the nozzle before shutting down the printer.
- Use fresh, approved ink compatible with your CIJ printer model.
6. Ink Drying Too Quickly or Smudging on Product
Symptoms:
- Ink smears or rubs off easily.
- Codes dry unevenly or not at all.
Possible Causes:
- Incorrect ink type for substrate material.
- Humidity or temperature affects drying time.
- Poor air circulation around the coding area.
Solutions:
- Choose the right ink formulation for your packaging material (plastic, metal, glass, etc.).
- Maintain optimal environmental conditions in your packaging area.
- If possible, add a small air blower or UV curing system near the printer output.
7. Frequent Alarm or Warning Messages
Symptoms:
- Error codes on display
- Frequent “Ink Low” or “Pressure Error” alerts
Possible Causes:
- Sensor malfunction or blocked filters
- Outdated firmware or software bugs
- Irregular ink circulation
Solutions:
- Refer to the printer’s error code manual for specific diagnostics.
- Clean or replace filters regularly.
- Restart and recalibrate the printer.
- Contact service support if the issue persists.
8. Communication or Connectivity Issues
Symptoms:
- Printer not syncing with production line systems
- Data transfer errors or printing delays
Possible Causes:
- Faulty network cable or port
- Incorrect printer configuration
- Software communication failure
Solutions:
- Check all cable connections and network settings.
- Update printer communication drivers and firmware.
- Reconnect to the network and restart both systems.
Preventive Maintenance Tips for CIJ Printers
A well-maintained CIJ printer can run efficiently for years with minimal breakdowns. Follow these maintenance practices:
- Daily Cleaning: Wipe the printhead and nozzle after every shift to prevent clogging.
- Weekly Check: Inspect filters, ink lines, and seals for leakage.
- Monthly Maintenance: Run a complete system flush and viscosity calibration.
- Use Genuine Consumables: Always use manufacturer-recommended inks and solvents.
- Proper Shutdown Procedure: Never abruptly power off the printer—use the standard shutdown mode to avoid ink drying.
When to Upgrade or Replace Your CIJ Printer
If your printer requires frequent servicing or print quality has degraded despite regular maintenance, it may be time to upgrade. Modern CIJ printers come with:
- Smart diagnostics and auto-clean features
- Energy-efficient designs
- Support for high-speed multi-line printing
- Integration with Industry 4.0 and IoT systems
Upgrading ensures higher uptime, reduced maintenance, and better print quality for demanding production environments.
Conclusion
CIJ printers are the heart of high-speed batch coding and marking operations. While they are built for durability and precision, occasional issues are inevitable. By understanding these common problems—and applying preventive maintenance—you can significantly extend the life of your printer and keep your packaging lines running without interruption.
At BT Print, we specialize in CIJ printers, TIJ printers, and laser marking machines that meet the needs of Indian manufacturers across industries. We also provide servicing, consumables, and technical support to ensure your coding systems perform at their best—every day, every shift.
Explore our range of Batch Coding Machines
and CIJ Printers to upgrade your production line with reliable and efficient coding technology.