Introduction Performance Report Introduction Thermal transfer printers need regular care to maintain their performance just like a car needs its oil changed. Typically, printer OEMs recommend cleaning the printhead after every ribbon. This assures print quality does not degrade over time and the head does not prematurely fail. Yet, research shows less than 20% of people follow the manufacturer's printhead cleaning recommendations. A primary reason people don’t clean the printhead is it is inconvenient and messy. Cleaning supplies are not always readily available at the printers, and traditional cleaning methods are time consuming - slowing down the printing process. Importance of Printhead Cleaning Printhead buildup is a normal occurrence in thermal transfer printing. Dirt and residue from the ribbon, stock, and environment are deposited on the printhead during the printing process. If the printhead is not cleaned regularly, the residue eventually becomes permanent and will create a barrier between the printhead element (dot) and the label. Blocked elements cause print quality problems such as lighter print, voiding and streaking, as well as shortened printhead life. Buildup and related problems can be prevented by regularly cleaning the printhead. Cleaning removes dirt and debris before it bakes onto the printhead elements. Figure 1 represents a magnified photograph of a clean printhead. The Figure 1 Clean Printhead rows of squares in the center of the photo are printhead elements or dots. Commonly, there are 203 dots per inch. Factors that Affect Buildup Complex label format, faster print speeds, high heat settings, and high volume printing are some extremely aggressive conditions in thermal transfer printing that accelerate printhead buildup. The type of printer and ribbon are other variables that affect the level and severity of buildup. All thermal transfer ribbons have a "backcoat" that serves as a protective layer between the printhead and ribbon's base film, allowing the ribbon to slide smoothly under the printhead. Because all backcoats leave some residue on the printhead, it is necessary to clean the printhead regularly to avoid buildup. Figure 2 below demonstrates how quickly buildup occurs when a printhead is not cleaned. The photographs represent buildup induced by aggressively printing with three leading ribbon brands and NOT CLEANING at each ribbon load. This amount of buildup was generated after 5 ribbons, and has no impact on print quality. However, the rate of buildup will progress in a similar fashion if the printhead is not cleaned. Over time, print quality will suffer and the printhead elements will burnout prematurely, requiring the printhead to be replaced.                         Brand A                                                                   Brand B                                                                  Brand C Figure 2 - Printhead Buildup when Not Regularly Cleaned (three leading ribbon brands) Performance Report A New Innovation - Clean Start™ Built-in Printhead Cleaner Clean Start was invented to encourage printhead cleaning and make it easy. Clean Start is a printhead cleaner that is built into the beginning of the thermal transfer ribbon. Clean Start is a thin, white film coated with a mild cleanser that gets pulled through the locked printhead at the start of each ribbon load to remove residue before it builds up. Clean Start was introduced in February 2004 on a wax thermal transfer ribbon. Based on strong demand, Clean Start was expanded to wax/resin and resin ribbons in late 2004. This Performance Report provides details on a series of tests performed to confirm the effectiveness of Clean Start and meets the following objectives: Ensure Clean Start does not, in any way, damage the printhead. Compare the buildup on a printhead when using Clean Start as a routine cleaning method versus not cleaning the printhead at all. Compare the effects of using Isopropyl Alcohol (IPA) vs. Clean Start to clean the thermal printhead. Test One - Clean Start Does Not Damage the Printhead The objective of Test One was to ensure Clean Start does not, in any way, damage the printhead. A new printhead was placed in a Zebra 140xi printer and 15,750 inches of Clean Start material was pulled through the printer per the operating instructions for Clean Start. In an actual application, approximately seven inches of Clean Start is pulled through at the start of each ribbon. This is equivalent to using Clean Start with 2,250 ribbons. Assuming a ribbon length of 1,476 ft, this translates to 39.9 million linear inches of ribbon. Once this test was done, the printhead was evaluated to see if any change had taken place. The printhead elements were not worn or scratched and performance remained flawless as the test images below demonstrate. Figure 3 - Before and After Pulling 15,750" of Clean Start over a Locked Printhead - No Abrasion Occurred Performance Report Test One Conclusion - Clean Start Does Not Damage the Printhead This test was conclusive. Prolonged use of Clean Start will not damage the printhead in any way. Using Clean Start every time a new ribbon is loaded is a safe way to keep printheads clear of residue and debris. Test Two - Clean Start vs. Not Cleaning at All Test Two was developed and performed to compare the buildup on a printhead when using Clean Start as a routine cleaning method versus not cleaning the printhead at all.