We run two types of print jobs: Boards and PVC Banners
Rollers must be correctly wound UP (PVC Banner, 19mm Foamboard) or DOWN (all other board stock)
UNI (unidirectional setting) when printing all Foamboard and Comp-Panel boards AND where 'uni' is specified in the filenames of other print file.
If QTY is greater than 10 for the board file, check the output against the Artwork in the Jobs folder on the PC to ensure we are not printing anything erroneous.
If total length of 1600mm PVC Banner jobs is less than 15m. continue printing PVC Banner on 2500mm stock as the waste of 2500mm stock 'sides' is preferable to the loss of 1600mm run-on required for loading fresh.
Checked the D4 every ~10 minutes when printing to avoid missing any quality issues that may arise. Click here for the GembaDoc Quality checklist.
Check the Flatbed run Sheets 2025 sheet to view the production plan. Highlighted in Yellow = Currently being printed. Highlighted in Green = Printed.
Smaller Quantities, Batches with higher file counts should be run first. (This Will clear more jobs off the board)
Always print Larger Batches with higher quantities of sheets on a new pallet to avoid burying smaller batches.
Quantities greater than 10 sheets must be checked against the client artwork. This can only be done once the first sheet has been printed once the Job numbers have been sighted on the board and looked up on the D4 PC. Check the 'Artwork' folder.
When Running boards the operator must ensure the next run / batches stock is setup and ready to go outside the print room. This helps us maintain efficiency of the printer and helps keep the flow of work through the business.
This could also involve splitting a full pallet.
Either pulling a new pallet down from the racks or Flagging it to a forklift operator to pull it down.
Building a pallet of stocks. EG: 3x 3mmpvc, 2x 2mm screen board and 10x 5mm foamboard.
Check the Job Sections Board to view the unprinted PVC banner jobs under 510gsm Matt Banner Single Sided"
Using the Job Sections Analysis sheet will help to gain a better visualisation of banner lengths per width / develop sequencing strategy / prepare new rolls of stock where necessary.
If you are running 2500 wide PVC you may avoid change-over and run up to an additional 15m of 1600 wide PVC banner jobs on the 2500 stock. If the total of 1600 job lengths exceed 15m, perform the change-over and print on 1600 stock.
If you are running future PVC banner, always print it before the same day / next day PVC banner. This will result in the future jobs being printed closer to the core and therefore be cut / finish after the more urgent jobs.
Each of the items below are linked to an SOP. (click the item to open the sop)
The Stacker and feeder have a different maintenance schedules to the main printer unit, which are all specified below.
An SOP is linked to each of the time-frames daily, twice weekly weekly & monthly.
Purge the print heads
Clean the Print Plate (silver area around printheads)
Clean the glass of the UV lamps With Windex. (Morning Shift Only)
Check Aerosol filter for soiling. (Change when necessary)
Check the carriage guide and lubricate.
Check Coolant level of the cooling unit.
Check the air filter of the cooling unit. (clean it When required)
Check main tank ventilation filters for soiling and replace if necessary.
Check air filters of the UV units. (Change when necessary)
Check and clean conveyer belt.
Check Encoder ruler and clean if needed.
Empty Waste ink container.
Check and replace UV filters if required.
Clean Acrylic panels Around the printer.
Wipe down the top of the printer and stacker and feeder.
Check Stock profiles are correct.
Check Estops Work (Rotate which e stop is pressed every week. each Estop has its own number eg:
Clean and Lubricate Guide Rails (2 vertical and 1 horizontal on each side of the carriage on both stacker and feeder)
Clean Drive Belts 1 vertical 1 horizontal each side 4 total each stacker and feeder. ( To access the vertical Belt you have to undo the cover).
Check that the feeder plates are tight.
Check that the shaker grippers are tight.
clean acrylic panels that have excessive soiling.
Replace any damaged grippers. (report when replacing)
Clean and Replace any damaged grippers. (report when replacing)
Clean and lubricate Drive chain.
Clean and Lubricate the guide rails and pipes under the tables.
D4 Maintenance manuals that are located in Z:\Printer Manuals\D4 Manuals can be found linked below: