Without a doubt, today’s press systems have improved print quality.
Upgrades in dampening equipment have provided better control over the application of fountain solution to the plate. These equipment changes have enabled the chemistry to become more specialized for individual printing applications.

With these changes, chemistry has progressed also. To improve print quality, fountain solution formulas can contain up to twenty five different ingredients. These ingredients, by their nature are fantastic print enhancers. However, left unchecked, in the dark confines of our press plumbing, they are also fantastic growers of bacteria. Bacteria consume these items, causing drastic changes in conductivity, pH, and make the fountain solution less effective. As the warmer seasonal temperatures are upon us, this bacterial growth increases. Certain bacteria can multiply twenty times in twenty minutes. We have all seen the slime buildup or experienced that “not so pleasant” smell as a result of higher temperatures and dampening system neglect. Your fountain solution should contain several specific biocides to reduce this growth. However, I say “reduce” because the combination of biocides in a fountain solution formula will not kill all of the bacteria in a contaminated system. It is designed to prevent bacteria growth in a dampening system. Even then, there are limitations to it’s effectiveness in a fountain solution formula.

Many customers ask the chemistry supplier to “increase” the biocide package in a fountain solution formula. From this perspective, more biocides will keep the dampening system cleaner for a longer period of time. However, this isn’t the answer. Simply adding additional or more aggressive biocide chemistry is one dimensional and falls short of a total solution to improve the printing process.

Keep in mind, the primary purpose of the fountain solution is not to keep the water system clean. First and foremost, fountain solution is designed to improve print quality. Synergy must exist with the ink, plates, and rollers in response to equipment demands. Quality printing is the primary goal.

Again, as warm weather increases, so does the need for increased system maintenance. Maintaining a sweet spot or a balance between printing performance and system maintenance is the key. The nature of biocides, peroxides, and chlorine are fantastic for keeping a pool clean, but not so friendly to printing plates and press equipment. Most of these “cleaners” are oxidizers which kill bacteria but also attacks surface metals. Continually overloading a live dampening system with increased biocides impacts the delicate balance of printing a newspaper. So if overloading a printing press’ fountain solution with increased biocides is not the answer, what is?

Some of the newer pressrooms have additional equipment to aid in keeping dampening systems clean. Water and system purification devices include various media filtration, ultra-violet lights, peroxide injectors, ozone systems, ultrasonic devices, and water chillers. These additions do help, but they are not a 100% effective solution.

To periodically “shock” a system is a sensible approach. By utilizing this method, the cleaners can be contained within the confines of the mixing cabinets, and the plumbing lines instead of being sprayed onto our costly press cylinders. Issues of equipment warranty and environmental compliance are kept in check as manufacturer’s recommendations are followed.

A comprehensive solution should include a scheduled maintenance plan, which includes periodic bacteria testing, fountain solution testing, and dampening system cleaning. Periodic testing of bacteria levels is proactive and will identify elevated bacteria levels far earlier than our senses will. Early detection of system bacteria prevents an impact to production operations and allows for more flexibility in cleaning the system. Work with your suppliers to identify the primary source of the bacteria; a contaminated water source, reverse osmosis system, a stagnant filter housing, or an inactive plumbing loop. Those potential sources of bacteria breeding need identified are corrected. A preventive maintenance schedule can be established based on current conditions and actual bacterial values instead of an estimated time interval. Pressroom labor can be more effectively utilized once this monitoring system is in place. Why clean every week, when once a month is proven sufficient? Why wait until dampeners clog and pressure loss impacts a press run to clean a system? Know what is going on through periodic testing.

So regardless of the age of the pressroom operation, one year or thirty years, a scheduled maintenance plan is the best approach. It can be scheduled to include a bacteria check, a system flush, filter changes, and other site specific requirements. Depending on equipment arrangements, water source, temperatures, and production loads, this maintenance plan may be performed weekly, monthly, or quarterly. And like other maintenance issues, it needs done.
System cleaning that is planned and completed will result in less dampener system problems. Less pressure fluctuation, spray bar nozzle clogs, and water pan build-up. Less filter issues, less surprises, and better performance from the fountain solution formulas. Ignoring the dampener system will not make its problems go away.

Don Gramling
Printing Services Manager
C&W Pressroom Products™