Ghosting or Double Image in Inkjet Printing: Causes and How to Resolve It | Cheef Inkjet

Ghosting or Double Image in Inkjet Printing: Causes and How to Resolve It

Ghosting or the appearance of a “double image” in inkjet printed text can reduce readability and cause rejection in industrial production. Whether using CIJ, TIJ, or DOD technology, such distortion usually points to mechanical movement, timing misalignment, or ink over-dispersion. This article outlines the main causes of ghosted prints and practical strategies for eliminating them.

Common Symptoms of Ghosting

• ⚠️ Characters have faint duplicates offset to one side
• ⚠️ Barcodes or numbers show a “shadow” line
• ⚠️ Text appears blurred even though the font is correct
• ⚠️ Issues worsen as production speed increases

Typical Causes and Solutions

1. Mechanical Vibration or Product Instability

• Cause: Conveyor or product jig vibrates during printing
• Fix:
  • Install anti-vibration pads or shock absorbers under the printer stand
  • Stabilize product movement with side guides or top belts

2. Printhead Misalignment or Shift

• Cause: Printhead not firmly fixed or mounted at an angle
• Fix:
  • Tighten mounting bracket and verify perpendicular alignment to product surface
  • Recalibrate head position for consistent print zone entry

3. Inaccurate Trigger Timing or Encoder Sync

• Cause: Delay between sensor detection and actual print is mismatched
• Fix:
  • Adjust print delay settings in milliseconds or pulses
  • Use encoder for accurate speed feedback, especially on variable-speed lines

4. Substrate Ink Absorption or Smear

• Cause: Ink spreads slightly before drying or is dragged across surface
• Fix:
  • Switch to fast-drying ink or add drying module (e.g., IR heater)
  • Check if product touches the print zone before ink sets

5. Re-triggering or Signal Bounce

• Cause: Sensor sends multiple triggers for a single product
• Fix:
  • Enable debounce function or set print inhibit time
  • Replace faulty sensors with better optical or laser options

Best Practices

• ✅ Test print at full line speed before live production
• ✅ Anchor all moving components (printer, head, sensor, guides)
• ✅ Run alignment calibration after equipment maintenance or relocation
• ✅ Use product-shaped jigs for irregular or small items

FAQs

• Can ghosting happen even if printing is clear at low speed? Yes—higher speeds amplify mechanical instability or delay mismatches
• Is ghosting a hardware or software issue? Usually mechanical, but software misconfiguration (delay/trigger) can contribute

Conclusion

Ghosting in inkjet printing is a sign of instability—whether mechanical, electrical, or timing-related. With careful calibration, vibration control, and smart layout management, clear and sharp printing can be restored. For alignment tools, encoder kits, or sensor upgrade advice, contact Cheef Inkjet at sales@cheef.cn.