Inkjet marking guns have become essential tools for manufacturers, warehouses, logistics teams, and field technicians who need fast, reliable, and mobile product coding. But even the best inkjet marking gun can experience printing issues when not maintained properly or used under challenging conditions. Understanding the most common problems—and knowing how to fix them quickly—ensures consistent code quality, reduces downtime, and protects your production traceability.

1. Faded or Light Print Quality

Faded print is one of the most common issues users face, especially when printing in fast-paced warehouse environments or on porous materials.

Main Causes

（1）Low ink density or depleted cartridge
（2）Incorrect ink type for the surface
（3）Printing too far from the substrate
（4）Cold operating temperatures
（5）Dirty or clogged nozzles

How to Fix It

1.Check ink levels and replace the cartridge if needed. Low ink often causes uneven density.
2.Match the ink to the material.
（1）Porous surfaces → water-based ink
（2）Non-porous surfaces → solvent-based ink
3.Adjust the printing distance (ideal: 2–5 mm).
4.Warm the device if printing in temperatures below recommended levels.
5.Clean the nozzle with a lint-free cloth and approved cleaning solution.

Pro Tip 

Industrial-grade solvent TIJ cartridges maintain better density on plastics, metals, and coated boxes—reducing fading by up to 60% compared to standard water-based options.

2. Smudging or Smearing on the Substrate

If prints smear after application, the problem is often compatibility or drying time.

Main Causes

（1）Incorrect ink for the material
（2）Touching or moving the product too soon
（3）Excessive ink output
（4）High humidity slowing ink curing

How to Fix It

（1）Switch to fast-dry solvent ink for non-porous surfaces.
（2）Increase drying time or airflow around the print area.
（3）Lower ink output in the printer settings.
（4）Avoid handling products until the ink has fully cured.

Pro Tip

Solvent-based inks cure in seconds on plastic, metal, aluminum foil, and glossy cartons—making them ideal for warehouses and packaging lines.

3. Inkjet Marking Gun Not Printing at All

This issue can be alarming, but usually the cause is simple.

Main Causes

（1）Cartridge not seated properly
（2）Protective tape not removed
（3）Hardware or connector error
（4）Firmware glitch
（5）Fully clogged printhead

How to Fix It

1.Reinstall the cartridge and confirm it “clicks” into place.
2.Remove any remaining protective tape or seals.
3.Restart the marking gun to refresh firmware communication.
4.Clean the printhead thoroughly.
5.Try a known-working cartridge to rule out hardware failure.

4. Misaligned or Distorted Prints

Uneven prints affect readability, especially for barcodes, QR codes, and expiration dates.

Main Causes

（1）Device shaking during operation
（2）Printing on uneven or textured surfaces
（3）Wrong DPI selection
（4）Improper line tracking

How to Fix It

（1）Stabilize the gun during printing; use two-hand support if needed.
（2）Enable auto-tracking on supported models.
（3）Increase DPI for detailed codes.
（4）Print on smoother areas when possible or increase ink density for rough materials.

5. Missing Dots or Broken Code Lines

A frequent issue for high-speed users or those printing on rough substrates.

Main Causes

（1）Clogged nozzles
（2）Dust or packaging fibers interfering with printing
（3）Cartridge nearing end of life
（4）Printing too fast
（5）Incorrect surface angle

How to Fix It

（1）Clean the printhead with approved cleaning solution.
（2）Wipe down dusty surfaces before printing.
（3）Replace the cartridge if nozzles are permanently blocked.
（4）Slow down print speed for improved nozzle firing accuracy.
（5）Adjust the gun angle to 90° for best contact alignment.

6. Ink Not Drying Fast Enough on Coated or Glossy Materials

This is especially common when printing on:

（1）film packaging

（2）glossy cartons

（3）aluminum foil

（4）varnished labels

How to Fix It

（1）Use fast-dry solvent ink specifically designed for non-porous materials.
（2）Activate quick-dry mode if your marking gun includes one.
（3）Reduce ink volume to improve curing speed.

Expert Note

Water-based inks are for absorbent surfaces only. If used on plastics or films, smudging and long drying times are unavoidable.

7. Ink Spreading or Feathering

This happens when printing on very porous packaging.

Quick Fixes

（1）Switch to water-based high-viscosity ink
（2）Reduce DPI slightly
（3）Print with lower ink density

This improves clarity without sacrificing contrast.

Preventive Tips to Avoid Future Printing Issues

✔ Clean the printhead daily
✔ Store cartridges in sealed packaging
✔ Use ink types suitable for your substrate
✔ Avoid extreme temperatures
✔ Maintain consistent printing distance
✔ Regularly update firmware on your inkjet marking gun

These small habits dramatically extend the lifespan of the printer and cartridge while ensuring sharp, professional codes.

Want Cleaner, Sharper, More Reliable Marking Performance?

If you're looking for a high-quality inkjet marking gun, the right ink type, or professional guidance for industrial coding:

➡ Contact us for expert recommendations and tailored workflow solutions
➡ Request a free consultation for your printing environment
➡ Get matched with the best inkjet marking gun for your production needs

Reliable coding starts with the right equipment—and the right support.