Why Does Inkjet Printing Smudge After Changing Packaging Suppliers?

A packaging change can affect how an inkjet code dries and stays on the surface, even when the printer and ink remain the same. However, smudging alone does not prove that the new packaging is defective. Compare the old and new packaging before changing equipment or committing to a production run.

This PTS Technology guide explains a practical troubleshooting approach for batch numbers, manufacturing dates and expiry-date printing. It is not a report of a particular supplier's test results.

1. Identify when the problem happens

• The print is unclear before anyone touches it: inspect the printing setup, movement, print distance and nozzle condition according to the printer manual. This is not necessarily an adhesion problem.
• The code smears when touched immediately: allow the ink to dry before wiping, stacking or handling the printed area.
• The code rubs off after drying: investigate ink and surface compatibility, surface condition and the handling the packaging must withstand. Dry-to-touch does not automatically mean strong adhesion.

2. Check what changed with the packaging

Ask the packaging supplier whether the outer film, laminate, coating or surface treatment has changed. Two packs can look similar but have different print surfaces. Also check for moisture, frost, oil or dust, and record the printer, cartridge and printing conditions instead of assuming the packaging is the only variable.

For frozen packaging, wipe off frost first and ensure the print area is clean and dry, with no visible moisture or condensation, before printing. Use only cleaning methods suitable for the packaging. Do not assume any solvent can safely clean every film or coating.

3. Run a controlled old-versus-new comparison

1. Keep identifiable samples. Label the old and new packaging with supplier, material and batch details where available.
2. Keep the printing setup consistent. Use the same printer, compatible ink cartridge, message and settings. Change one variable at a time and record any adjustment.
3. Prepare comparable print areas. Check both surfaces are clean and dry. Do not compare a dry sample with a wet or frosted one.
4. Record drying time. Start timing immediately after printing. Check both samples at the same recorded intervals, using separate printed areas where practical. There is no single drying time that applies to every ink, packaging material and environment.
5. Compare handling resistance. After drying, use a consistent wiping material, number of strokes and similar pressure for an initial comparison. Record whether the code stays readable, smears or loses ink. This is an informal screening check, not a certified test.
6. Check the real process. Evaluate samples under the storage and handling conditions relevant to your product before approving the new packaging for production.

4. Keep a simple test record

• Packaging supplier, material, batch and the actual side printed.
• Printer model, cartridge identification and printing settings.
• Surface condition and relevant working conditions.
• Time between printing and checking, plus the checking method.
• Photos before and after handling, with notes on code readability.

If the original packaging also starts performing differently, check the printer, cartridge and operating conditions as well. If only the new packaging behaves differently, discuss the surface specification and ink compatibility with your suppliers; it still does not automatically mean either product is faulty.

Related PTS products and application examples

For model information, see the BENTSAI 6205 / 6210 printer series. For packaging applications, explore our Food & Beverage Coding Solutions.

Our 6205 frozen-packaging testing article illustrates why surface preparation and time before wiping matter. Its drying guidance relates to that application and must not be treated as a universal guarantee for other packaging.

Frequently asked questions

Will a faster-drying ink always solve the problem?

No. Drying and adhesion are different considerations. The ink still needs to be compatible with the actual print surface and suitable for the intended handling conditions.

Do I need a new printer after changing packaging?

Not necessarily. First compare samples and check the existing printer, cartridge and setup. Any change of ink or equipment should follow a suitability assessment rather than guesswork.

Ask PTS to review your packaging samples

Contact PTS Technology in Malaysia with old and new packaging samples, your printer model, cartridge details, photos of the issue and the time before wiping. Include your storage and handling requirements so we can discuss suitable testing and available options. Suitability must be confirmed on your actual material.

Main image: illustrative comparison layout, not actual customer test results.