11 causes and solutions for wrinkles in sublimation

During the thermal transfer sublimation process, users of thermal transfer roller machines may encounter the problem of paper wrinkles or creases.

Next we will list 11 major causes of wrinkled paper and their solutions.

1) Blanket doesn't feed in completely: If the blanket doesn't feed in completely, this can cause wrinkles in the paper because the paper isn't being pulled taut across the surface of the drum. If it is calender sublimation machine that automatically feeds the blanket, you can press the button again to see if the blanket will advance a little further. Observe whether the blanket is in the same position as before. If not, probably there is something wrong with the limit switch. If it is a roll heat transfer machine that manually feeds the blankets, you can manually turn the handwheel to see if it can move forward a little further.

2) One side of the blanket is not tight enough: If one side of the blanket is not tight enough, this can cause the paper to bunch up on the looser side, resulting in wrinkles. A blanket that is loose on one side and tight on the other may be due to: The supplier itself does not provide buyers with blankets with the same circumference on the left and right sides, and the machine itself cannot adjust the circumference of the blanket properly. You can stand on the back of the machine and gently press the blanket from left to right with your hands to see if it is tight enough. If you are not sure, you can record a video and send it to the supplier for confirmation. Then adjust the felt tensioning shaft on the calandra sublimation to make the tension consistent on both sides.

3) Blanket is too old or damaged: Blankets that are old or damaged (the blanket may also be worn out from being used for too long) can develop uneven wear patterns, which can contribute to wrinkled paper.
After long-term use, the circumference of the blanket is stretched due to stretching, and the adjustable range of the calendar heat press machine itself has reached the extreme, and it cannot be adjusted to make it tighter. At this time, the belt may be too loose, causing wrinkles.

4) Blanket goes to a side: If the blanket goes to one side, this can cause uneven tension across the drum, which can lead to wrinkles in the paper.
If the machine does not have an automatic correction system, the felt will easily produce wrinkles during the deviation process. Or the automatic correction system is malfunctioning and cannot correct the correction automatically. Then you need to contact the supplier to help solve the automatic correction problem.

5) Blanket feeding shaft lost balance: If the feeding shaft for the blanket is unbalanced, this can disrupt the even tension of the blanket across the drum, leading to wrinkled paper. Use a ruler to measure whether the left and right sides of the shaft are at different positions from the edge of the machine wall panel. If they are inconsistent, you can loosen the left and right racks, adjust them until they are consistent, and then tighten them.

6) Sublimation paper isn't flat enough before feeding in: If the sublimation paper isn't completely flat before being fed into the roller heat transfer machine, this can contribute to wrinkles. You can adjust the tensioner to ensure that the paper is tightened.

7) Protective paper tension isn't set well: The tension on the protective paper that's used to prevent the sublimation ink from getting onto the blanket can also contribute to wrinkles if it's not set properly. The tightness of the protective paper can be adjusted through the tensioner above the main unit. If the protective paper on the left and right ends does not enter the machine at the same time, it will cause one side to be loose and the other to be tight. If the tension on the left and right ends of the protective paper is inconsistent, you need to tear off some additional protective paper and put more protective paper on the looser end until the tension is consistent on both ends.

8) Pressure isn't proper for the substrate: If the pressure being applied to the substrate is too high or too low, this can cause wrinkles as the substrate isn't being held taut enough. Generally, for low-gram fabric, the pressure needs to be increased, and for high-gram fabric, the pressure needs to be reduced. For thicker and fluffy substrates, pneumatic pressure is generally not turned on.

9) Fabric tension isn't proper: If the fabric being sublimated onto isn't taut enough, this can contribute to wrinkles in the final result. For polyester fabrics with higher spandex content, tensioners are generally not required. For fabrics that have no elasticity, they generally need to go through a tensioner and adjust so that the fabric is tightened.

10) Temperature and speed aren’t appropriate for the substrate:
For roll heat press with a drum diameter of 210mm, temperatures below 200°C are generally used. Excessive temperatures will cause creases or wrinkles in the paper. For thermal transfer machines of all diameters, the speed needs to be controlled within a reasonable range.

11) The drum is deformed: If the drum that the sublimation paper is wrapped around is deformed, this can lead to uneven tension across the paper and ultimately result in wrinkles. If the drum wall is thin, long-term operation at high temperatures may cause it to deform. If the drum is not oiled and burned dry for a long time, it will be easily deformed. Or the roller on the machine provided by the supplier itself is not processed well, and the circumference is not exactly consistent from left to right. It can be judged by observing whether the drum is deformed or by measuring the circumference of the drum. If all other possible factors have been eliminated and the circumference of the drum has been measured to confirm that the drum is deformed, the drum needs to be replaced.