Inkjet printheads are prone to clogging, causing significant inconvenience for users. If not promptly addressed, clogged printheads can disrupt production schedules and, in severe cases, result in permanent damage, rendering the printer inoperable and increasing operational costs. Proper maintenance is essential to minimize clogging and ensure smooth printing operations. This article outlines six common causes of printhead failure and four essential maintenance practices.

Six Common Causes of Printhead Clogging

1. Ink Depletion

When the printhead runs out of ink, the piezoelectric ceramic components continue working, but no droplets are ejected without ink. In such cases, a simple ink-pressurization cleaning method can usually restore normal operation.

2. Air Blockage

Air trapped inside the printhead can prevent ink from being properly ejected. If this occurs, ink-pressurization cleaning should be attempted first, as the ink pressure can often push out trapped air. In some cases, however, air bubbles may persist inside the printhead. When this happens, the best course of action is to wait for the bubbles to dissolve naturally into the ink (a process known as degassing).

3. Ink Drying or Contamination

If the printhead is left unused for an extended period without proper humidification, residual ink can dry inside, leading to clogging. Similarly, contaminants can enter the printhead and cause blockages, much like dried ink residue.

· Minor blockages can be cleared using ink-pressurization cleaning.

· Severe cases may require flushing the printhead with a cleaning solution via a syringe. Care should be taken to control the pressure, as excessive force may damage the adhesive holding the nozzle plate, leading to ink leakage.

· If cleaning solutions fail, ultrasonic vibration can be used to dislodge blockages. However, ultrasonic cleaning carries a risk of damaging the printhead and should be used with caution.

4. Physical Damage

Physical contact with printing materials, foreign objects, low-quality wipers, or substandard capping stations and humidification pads can cause irreversible damage to the nozzle plate. Since this type of damage is permanent, prevention is key.

5. Electrical Damage

Improper data cable connection, power supply fluctuations, or ink leakage onto the printhead’s circuit board can cause electrical failure, often causing multiple nozzles to stop working. Due to the high level of integration in printhead circuitry, such damage typically results in printhead failure, requiring a full replacement.

6. Piezoelectric Ceramic Degradation

Over time, the piezoelectric ceramic components responsible for ink ejection may degrade, reducing their ability to function properly. While most manufacturers design printheads to withstand billions of ink ejection cycles, real-world usage often leads to failure due to the issues mentioned above rather than natural aging.

Four Essential Practices for Printhead Maintenance

1. Ink Supply System Maintenance

Many users overlook the importance of maintaining the ink supply system until ink leaks occur. Over time, ink tubing and ink dampers accumulate impurities from the ink. Some low-quality ink tubes can also react with the ink, dissolving contaminants that get carried into the printhead.

· Avoid using substandard ink tubes and dampers.

· Regularly replace ink filters and dampers.

· Periodically replace aging ink tubes to prevent blockages and contamination.

2. Proper Humidification

Humidification is one of the most critical aspects of inkjet printer maintenance. If a printhead is left unused for a certain period, it must be properly humidified.

· Before humidification, clean the capping station and humidification pad.

· Never reuse humidification pads to prevent contamination.

· Ensure a tight seal between the nozzle plate and the humidification pad to prevent exposure to air.

3. Prompt Nozzle Cleaning

If minor nozzle clogs are ignored, they may worsen over time. What starts as a minor obstruction can eventually lead to a full blockage, requiring extensive cleaning or even rendering the nozzle unusable.

· Always check for nozzle clogs before shutting down the printer.

· Print a nozzle status report before powering off and document the results for future reference.

· Compare nozzle status reports over time to track clogging patterns and take preventive action.

Conclusion

Printhead maintenance is crucial to prolonging the life of an inkjet printer  and ensuring consistent print quality. By understanding the causes of clogging and implementing regular maintenance practices, users can significantly reduce downtime and operational costs. A proactive approach to ink system maintenance, proper humidification, timely nozzle cleaning, and careful handling of printheads will help prevent common failures and extend the longevity of printing equipment.

We are pleased to invite you to our events where we will showcase various segments of our offer. In addition to interesting presentations, you will also have the opportunity for one-on-one questions and discussions with our experts.

Event Location:
Gajcom d.o.o., Pot heroja Trtnika 45, Ljubljana – Vevče

Schedule:

• Presentation: 10:00–11:00
• Q&A Session: 11:00–13:00

Event Topics:

• January 15, 2025: Open Day for DTF Printing
  Description: DTF (Direct to Film) is a modern printing technique that allows for the transfer of colorful designs onto various textile and other materials (DTF transfers). The process involves printing the design directly onto a film, which is then transferred onto the product using a heat press. DTF technology offers vibrant colors, high durability, and versatility for printing on various materials. During the event, we will showcase products from Hanrun Paper and Unity, featuring high-quality films, inks, and powders for DTF printing.

• February 12, 2025: Sublimation Day with Sawgrass and Chromaluxe
  Description: Sawgrass is a leading manufacturer of sublimation printers, cartridges, and paper designed for personalizing smaller products such as puzzles, keychains, T-shirts, and other promotional items. Chromaluxe offers premium photo panels made from high-quality aluminum or MDF, coated with multi-layered sublimation coatings for exceptionally vibrant and durable color transfers. At the event, you can see the Sawgrass printers in action combined with top-quality sublimation products.

• March 12, 2025: Open Day for Screen Printing with Grafco
  Description: Grafco is an Italian manufacturer specializing in high-quality screen printing inks, cleaners, and accessories for textile products. Their inks are known for exceptional coverage and ease of use, suitable for both beginners and experienced printers. Did you know that Grafco can create a custom ink specifically for your needs, enabling you to print using various techniques and on materials that may currently pose a challenge?

• April 16, 2025: Open Day for DTF Technology
  
  

• May 14, 2025: Sublimation Day with Sawgrass and Chromaluxe
  
  

• September 17, 2025: Open Day for DTF Technology
  
  

• October 15, 2025: Open Day for Screen Printing with Grafco
  
  

• November 12, 2025: Sublimation Day with Sawgrass and Chromaluxe
  
  

Event Registration

Due to limited availability, we kindly ask you to confirm your attendance at gajcom@sitotisk.net. If there is significant interest, additional dates will be organized as needed.

Do you have additional questions?
If you would like to explore a specific topic in more detail, you are always welcome to schedule a personal meeting. We are here to provide you with advice and support in your work.

We look forward to meeting you!

1. Method and Transfer Process

2. Print Quality and Durability

3. Versatility and Application

4. Speed and Cost

5. Key Advantages and Disadvantages

Conclusion

DTF printing allows for quick and high-quality customization of graphics on textiles. To ensure a superb final result, it is crucial to properly prepare the file for printing.

In this guide, you will learn:

• which formats are most suitable,

• how to set up the color space,

• what to watch out for with white color and backgrounds,

• and how to safely send your file.

📁 Recommended File Formats

For successful DTF printing, we accept the following formats:

• PDF – for vector graphics (e.g. logos, text)

• PNG – for bitmap images (photos, illustrations)
  → size 1:1, resolution at least 300 dpi

The file must be finalized – we print exactly what we receive. If you need additional help or processing, you can order it separately.

🎨 Color Space – RGB or CMYK?

• RGB: more vibrant, intense colors – most common choice

• CMYK: more accurate color reproduction (e.g. for precise shades)

➡️ We recommend RGB, as most clients want the most vibrant colors possible. The difference between the two is usually minimal, but if you need a very precise shade, please let us know in advance.

🖼️ Resolution and Ratio

• Use 300 dpi

• Prepare the design at actual size (1:1)

• For PNG formats, remove the background if it is not part of the design

⚪ Handling White Color

In DTF printing, white is applied as a separate layer – it is not “default”, but must be specifically included in the design.

• Everything marked as white will be printed in white

• Do not change white to another color

• If you don’t want white, use a transparent background

🧽 Backgrounds and Transparencies

• Remove backgrounds you don’t want on the final product

• Do not use transparent layers – they are not interpreted correctly

• If using images with gradients, test before printing

🧩 Combining Graphics on Sheets

For greater efficiency in ordering:

• Arrange graphics on a printing sheet up to 56 cm wide

• Leave at least 4 mm of straight margin between designs for easier cutting

• You can prepare one design and indicate the number of repetitions in the filename (e.g. _logo_5x.png)

📌 This way, we optimize material usage and provide you with a better price calculation.

📤 Sending Files

Send your file:

• via email to dtf@sitotisk.net (if the file is not too large)

• or via WeTransfer.com – make sure to send an additional confirmation email

⚠️ If you do not receive a response within 24 hours, check your spam folder or contact us – sometimes links from WeTransfer end up in junk mail.

❗ Common Mistakes (and How to Avoid Them)

• ❌ Incorrect resolution (e.g., 72 dpi) → use 300 dpi

• ❌ Missing white ink → clearly indicate it in the design

• ❌ Transparent layers → remove them

• ❌ Images without a background → ensure the background is truly not included

• ❌ Unclear layout on the sheet → use even spacing

✅ Quick tips for preparation:

• Maximum width: 56 cm

• You can place designs vertically or horizontally

• If you are unsure, ask us before submission – we are happy to help

• Use programs: Illustrator, CorelDraw, Photoshop, Canva, Gimp, Inkscape, Photopea.com, etc.

📩 Are you ready?

Send your design to dtf@sitotisk.net and order premium custom DTF transfers.
📦 Minimum order quantity: 1 linear meter
🎯 Place your order here: Creation of premium DTF transfers

• DTF Transfers for T-Shirt Printing 15,00 € + VAT
• Production of Premium DTF Transfers 15,00 € + VAT

Why?

To achieve optimal results in DTF printing, it is crucial to create a custom printing profile for each combination of ink and film. This process ensures that color shades are accurately reproducible, which is especially important for complex customer color requirements.

Why do we need individual profiles for ink and film?

Each combination of ink and film has its unique properties, such as saturation, transparency, and adhesion, which affect the final appearance of the print. Differences in texture and chemical composition between films, as well as the specific properties of each ink (e.g., saturation and pigmentation), mean that the same profile is not usable for all combinations. Without the appropriate profile, shades may deviate from desired values, leading to customer dissatisfaction and additional costs for reprinting.

The process of profile preparation

Preparing a printing profile for DTF requires precise setup and calibration of the printer for each combination of ink and film. The process includes:

1. Testing shades and saturation: each combination of ink and film is tested with different intensities to achieve the best color values.
2. Temperature and pressure settings: during profile preparation, temperature, time, and transfer pressure are also adjusted, as these factors affect the final shade.
3. Calibration of optical reading: using a color spectrophotometer, the accuracy of color shades on each film is checked, then printer settings are adjusted.

Advantages of using individual profiles

By creating specific profiles for each combination of film and ink, we ensure that:

• Shades match expectations: we achieve the desired color accuracy, which is essential for high-quality projects.
• We improve printing consistency: profiled printing results are consistent, regardless of material or color.
• We reduce the number of repetitions: by reducing the need for reprinting due to incorrect shades, we save time and costs.

Conclusion

In DTF printing, preparing individual profiles for each combination of ink and film is fundamental to achieving high-quality results. Precise profiling allows control over all shades and ensures that the final print meets customer expectations, while optimizing the efficiency of the entire printing process.

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This time, we received special training conducted specifically for us by the director and owner of Grafco, which employs 45 people.

Mr. Gianpaolo Coin is a chemist at heart, his knowledge is vast, and we haven’t yet encountered a problem he couldn’t first explain and then solve. This time as well, he introduced us to quite a few innovations and improvements that will surely benefit everyone using Grafco inks and additives in screen printing. Positive changes have occurred in the field of water-based inks for textiles, plastisol inks, as well as additives and cleaners.

CONSTANT AND FRESH STOCK

In Treviso, Italy, Grafco’s main office, warehouse, and mixing facility are located. The company also has several branches across Italy. For over 20 years, Gajcom has been ensuring a constant stock of inks and additives for screen printing from the regular range, and for some customers, we also supply custom-made ink.

Currently, the stock levels are good, prices are still competitive, and the quality of the products has already convinced many of you. For those of you considering switching to Grafco products, we can assure you that the transition is not painful. At Gajcom, we successfully made the transition 20 years ago, but it still required a significant amount of effort on our part at that time. In fact, we had to invest more in the change than you will have to now if you decide to make the switch.

We changed our t-shirt printing ink supplier due to the poor availability of the inks we previously used. The Slovenian market was not of interest to Grafco, so we had to negotiate both the import and distribution with them. We are still one of the smaller distributors, but according to Mr. Coin, we are reliable, and he admires our determination and resilience 🙂 Certainly, the satisfaction is mutual. In the picture are Mr. Gianpaolo Coin, the owner of Grafco srl, and Mr. Robert Kaltnekar, the owner of Gajcom d.o.o.

THOUGHTS …

The screen you will be printing on should be properly tensioned and the mesh chosen should be appropriate for the design. For large areas or wider surfaces, use a coarse mesh, and for halftones or fine lines, use a fine mesh. The hardness of the squeegee is also important, as it affects the extrusion of the ink through the screen. Our printers use a medium variant and employ a medium-hard rubber (75 SH). A very important thing for optimal ink extrusion is also the pressure of the squeegee, which should be even across the entire design and should not vary.

A single stroke of the squeegee will never yield good results because the first application of the ink only fills the holes in the fabric and creates a smooth base. The actual result is visible after the second stroke. The rule always applies – when printing on colored shirts, the first print is for the shirt, the second and subsequent prints are for the design.

PLASTISOLNOT COLORS

With plastisols, we can achieve even better whiteness by adding an additive R10 to the white ink. Its function is to puff up the ink slightly, thereby improving coverage.A little will suffice, because if we overdo adding the R10 additive, washing fastness and rub resistance will decrease. Correct usage does not reduce resistance.

Warning!

Always test color fastness before printing series.

Have you ever gotten a beautifully printed white T-shirt, soft to the touch, made from pure cotton? But after the first wash, the print wasn’t as bright anymore, as if it had washed out. The print had “faded”. Well, that’s fibrillation.

The softer the T-shirt feels to the touch, the more “fluffy” it is, the higher the chance of fibrillation. Some brands are particularly prone to fibrillation because they use yarn made from short fibers. Cotton fibers that make up the threads used to manufacture T-shirt fabric vary in length. Yarn made from short fibers is less processed and consequently cheaper. You could say it’s also more eco-friendly, although that depends on your perspective on environmental issues… Brands that, in our experience, use short fibers include Sol’s, B&C, Gildan, among others in certain models. This doesn’t mean these aren’t good T-shirts. They are; these T-shirts are great, wearable, maintain their appeal for a long time, and also print beautifully. However, it’s important to consider the high likelihood of fibrillation, especially on white T-shirts from these brands, during printing.

Because it is actually difficult to predict in advance which shirts will fibrillate and which will not – even with many years of experience, it is still sometimes hard to judge in advance whether we need to be careful or not, we prefer to always be careful and approach printing on white shirts of all brands and models (also of different weights, as weight greatly influences the susceptibility to fibrillation) a bit differently.

We approach preventing fibrillation differently for different types of printing.

If we are printing DTG, it is also sensible to use pretreatment fluid on white shirts. It is necessary to ensure that enough fluid is applied, that it is smoothly rolled, evenly applied, and of course, properly dried. Some printers also print an underlayer of white ink on white shirts that tend to fibrillate… an interesting trick that also increases the print’s durability. Never print on old pretreatment. Although it’s possible to prepare shirts with pretreatment fluid in advance, we advise against printing on shirts that have waited a long time… The components of the fluid simply react better with white ink if they are fresher.

In screen printing, there are many ‘tricks’ that are actually entirely part of the technological process, but most printers like to skip them to reduce costs. T-shirts can be printed multiple times. Each layer of ink reduces fibrillation. Additional (underlaid) layers of ink can be transparent, white, or gray, and sometimes it is possible to use the same ink that you are printing as the underlay color – you simply print multiple layers. Fibrillation is also reduced if you use enough ink, which means you need to use a sufficiently fine mesh and a well-sharpened squeegee, which you push at the correct angle, with the right speed and force … Well, a lot more could be added here. Namely, the screen printing process is influenced by 100 factors. If all factors are considered and consistently followed, then we print according to the technological process. As soon as one factor is omitted, a good print becomes quite the magic trick 🙂