23 Factors That Easily Cause Prepress Plate-Making Equipment Failures

Prepress plate-making equipment is one of the most precision-critical systems in modern printing production. In real-world operation, however, a large proportion of equipment failures are not caused by inherent defects, but by external factors such as environmental conditions, maintenance practices, and daily operating habits.

These causes are often diverse and cumulative. As a result, effective troubleshooting and prevention must be based on actual operating conditions rather than isolated assumptions.

Based on long-term maintenance and technical service experience in the printing industry—particularly in high-accuracy applications such as book printing—the following 23 factors are summarized as the most common causes closely related to prepress plate-making equipment failures. Careful control of these factors can significantly improve equipment stability and reduce unexpected downtime.

1. Dust

Prepress plate-making equipment, especially scanners, imagesetters, and CTP systems, are extremely sensitive to dust. Dust contamination can damage optical paths, sensors, and mechanical parts, making routine cleaning the most important task in daily maintenance.

2. Oil Contamination

Almost all mechanical systems require lubrication. Over time, lubricating oil can mix with dust, heat, and metal particles, forming oil sludge that increases resistance, causes localized overheating, and accelerates mechanical failure.

3. General Dirt and Grime

Dirt includes oil contamination and airborne particles combined with moisture. Although early accumulation may not cause immediate problems, long-term buildup can damage displays and sensitive electronic components.

4. Material Residue Adhesion

This issue is common in processors and proofing machines. Chemical reactions between film materials and developer solutions can produce residues that adhere to rollers. Proofing ink can also stick to ink rollers and rubber drums if not cleaned promptly.

5. Wear

Wear mainly affects frequently moving parts such as bearings, lead screws, and clamps. Proper and timely lubrication is the most effective way to slow wear and extend service life.

6. Vibration

Vibration can lead to both mechanical malfunctions and output quality issues. In addition to correct installation, equipment levelness and foundation stability should be checked regularly.

7. Loosening

Long-term vibration and operation can cause screws and fasteners to loosen. Routine inspection and tightening are essential preventive measures.

8. Leakage

Leakage of cooling or protective fluids—often caused by aging components or impact damage—can result in overheating and burnout, especially in lamp and cooling systems.

9. Corrosion

Volatile liquids and chemical residues can damage both metal and non-metal components. Failure to clean residues in time is a major cause of corrosion.

10. Creep

Creep develops slowly and is often difficult to detect. It can affect mechanical alignment or electronic parameters, requiring careful observation during inspections.

11. Stress Deformation

Improper adjustment after operation may lead to long-term stress, causing deformation of mechanical structures or circuit board slots.

12. Scratches

External impacts during operation may cause scratches on critical surfaces such as scanner drums or imagesetter cylinders, directly affecting output quality.

13. Cracks

Cracks usually result from prolonged excessive pressure or load. Once cracks appear, replacement is generally recommended, as repairs may cause secondary damage.

14. Overheating

Electronic components generate heat during operation, and mechanical friction also produces heat. Cooling systems must function properly, and operating temperatures should be monitored regularly.

15. Abnormal Noise

Unusual sounds often indicate wear, misalignment, or overheating. Equipment should be stopped immediately for inspection to prevent fault escalation.

16. Short Circuits

Short circuits are commonly caused by aging components or human error and are often accompanied by secondary damage. Power should not be restored until the root cause is fully identified.

17. Poor Insulation

Heat accumulation and aging reduce insulation performance, increasing the risk of short circuits. Adequate safety margins should be ensured during component replacement.

18. Poor Electrical Conductivity

Conductors, switches, or relays may fail to conduct current properly due to contact resistance or electrical performance issues. These problems are usually identified through powered testing.

19. Fatigue

Continuous long-term operation causes mechanical and electronic fatigue. Even equipment designed for continuous use benefits from 1–2 hours of daily downtime.

20. Rust

Rust forms on metal components due to oxidation, often caused by insufficient lubrication or protective oil, particularly in moving parts.

21. Parameter Drift

Parameter drift refers to the gradual deviation of performance parameters, often caused by overload conditions or electrical design limitations.

22. Poor Lubrication

Insufficient lubrication or excessive oil temperature leads to direct metal-to-metal contact, accelerating wear and causing mechanical failure.

23. Component Degradation

Electrical surges or material quality issues can cause component degradation. Replacement parts should be properly tested to prevent secondary failures.