A new client recently approached us with a request: “We want the best printing and the best ink for our cosmetic packaging.” At Auber Packaging, we have always used inks that undergo rigorous testing to ensure they are perfectly suited for our packaging production processes. These inks have maintained stable quality over time, so we were a bit puzzled by this sudden request.
Of course, we could source more expensive inks for the client. However, switching to new inks would require us to re-test their compatibility with our production machinery—a process that demands time and may involve material waste. Additionally, these specialized inks typically require large minimum purchase quantities, often enough to produce millions of units. Considering cost-effectiveness, replacing our existing inks did not seem like the optimal solution for either us as manufacturers or the client.
To address this, we initiated deeper communication with the client to understand the root cause of their request. It turned out that the client had encountered issues with their previous samples: some areas of the silk screen printing were missing, and they could even scrape off parts of the print with their nails. When we reviewed the client’s video footage, we noticed a key detail: other prints of the same color on the same packaging remained intact and could not be scraped off. We then advised the client to test these unblemished prints of the same color, and confirmed that the ink adhesion was strong with no signs of peeling.
This led us to explain the concept of printing gaps (or “missing prints”) to the client— a common quality issue in silk screen printing that often gets mistaken for poor ink quality. Printing gaps refer to discontinuous, broken, or missing areas in printed patterns or text, which broke the integrity of the design. In the client’s case, the uneven peeling and localized missing prints were typical manifestations of this issue, rather than a problem with the ink itself.
Printing gaps in silk screen printing on cosmetic packaging usually arise from specific production variables rather than the ink’s overall quality. For example: If the screen stencil is contaminated with dust or residual ink before printing, it can block the mesh and prevent ink from transferring evenly, causing missing areas. Uneven printing pressure or incorrect machine speed can also lead to incomplete ink transfer—too much pressure may scrape off fresh ink, while too little pressure fails to push ink through the stencil properly. Additionally, inadequate adjustment of the gap between the stencil and the packaging surface can result in partial non-adhesion of the ink.
To prevent such issues and ensure consistent quality, we implement strict control measures throughout the production process:
- Pre-printing and in-process stencil maintenance: We thoroughly clean the screen stencil before production to remove dust, residual ink, or debris. During printing, operators continuously monitor the stencil’s condition to address blockages or contamination promptly.
- Machine calibration and monitoring: We conduct comprehensive machine setup before production, ensuring optimal running speed and uniform pressure to guarantee smooth ink transfer. Operators also keep a close eye on machine performance during production to adjust parameters if anomalies occur.
- Strengthened in-process inspection: We have established strict in-process inspection protocols, with dedicated staff checking print quality at regular intervals. Detailed records are kept for each batch, documenting parameters, inspection results, and any adjustments made, allowing for full traceability.
By focusing on these critical control points, we can effectively prevent printing gaps and ensure strong, consistent ink adhesion on cosmetic packaging. At Auber Packaging, our commitment to quality lies not just in using reliable inks, but in mastering the entire production process to deliver flawless results.
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To learn more about the customization of squeeze tubes, websites: //www.cosmetic-tube.com/ or //www.auberpackaging.com/
