Intermittent Printing in Inkjet Coding: Causes and Fixes

When your inkjet printer occasionally skips prints, produces incomplete codes, or stops printing entirely during continuous production, it’s known as intermittent printing. This issue affects production consistency, traceability, and compliance. Whether you’re using CIJ, TIJ, or DOD, the root causes are often predictable—and fixable.

Common Symptoms

• ⚠️ Characters randomly missing or partially printed
• ⚠️ Printer stops printing for a few products, then resumes
• ⚠️ Dots appear faded or absent at regular intervals
• ⚠️ Nozzle appears clean, but print is inconsistent

Top Causes and Fixes

1. Unstable Trigger Signal

• Cause: Product sensor failing to trigger consistently
• Fix:
  • Check cable and sensor alignment
  • Replace worn or dirty sensors
  • Switch to high-speed optical or laser sensor for better accuracy

2. Ink Supply Disruption

• Cause: Air bubbles, clogged filters, or low pressure
• Fix:
  • Flush ink system and bleed air from lines
  • Replace ink and makeup filters
  • Monitor ink tank levels—auto-fill system may be malfunctioning

3. Encoder Malfunction

• Cause: Encoder fails to report motion accurately
• Fix:
  • Inspect encoder mount and roller contact
  • Check pulse signal with oscilloscope or diagnostics tool
  • Replace encoder if faulty

4. Nozzle or Cartridge Issue (TIJ/DOD)

• Cause: Dry nozzle, bad cartridge chip, or improper insertion
• Fix:
  • Clean or replace printhead
  • Use OEM-approved ink cartridges
  • Reinsert cartridge and check recognition status

5. Software or Layout File Error

• Cause: Faulty variable field, barcode logic, or font encoding
• Fix:
  • Recreate print job using updated software
  • Clear cache and reload layout files
  • Test with a basic fixed-text message to isolate the problem

Prevention Tips

• ✅ Perform daily nozzle checks and test prints
• ✅ Replace filters and inspect ink lines monthly
• ✅ Secure encoder and sensor cables against vibration
• ✅ Keep spare sensors and cartridges on hand for quick swaps

FAQs

• Why does the print skip only sometimes? Likely due to inconsistent sensor signals or ink flow irregularity
• Should I replace the printhead? Only if cleaning, re-seating, and diagnostics fail to resolve the issue

Conclusion

Intermittent printing is frustrating—but usually resolves through methodical diagnosis of sensors, ink flow, and signal stability. Regular maintenance, proper cabling, and verified consumables are the keys to reliable printing. For help with replacement parts or service plans, contact Cheef Inkjet at sales@cheef.cn.