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Aqazi81, If you are encountering an excess of anti setoff spray issue often we found these lamps helpful to detect too much offset spray on the sheet. We run 44" and 50" presses 6 colours plus coater and run high ink coverage jobs for packaging. Every now and then no matter how good your spray...

Have you tried some Food Grade Silicon spray on the blade between cuts

Here are a few I can think of if excess powder is used and I'm sure there are many others. Sheet will have a rough 'sandpaper' feel to it Uneven gloss with dull and glossy areas. Piling on the plate/blanket Spray residue in the equipment. Slip would be poor if you are putting product through...

is the sheet UV coated or some other type of coating, we had to use special coatings for our foil I think they are referred to as Stampable/Imprintable coatings also make sure there is no Silicon in the ink or coating

Rent a DI unit for a couple of months and see if that helps https://www.axeonwater.com/blog/deionized-water-ro-water-vs-di-water/

XRite eXact Advanced Xact provides the most versatile aperture set. You can meet different workflows needs and patch sizes when compared to other instruments: 1.5mm, 2mm, 4mm, & 6mm. eXact’s 2mm spot size is the most popular by capturing a sufficient number of printed dots but enables good...

Do your large presses use offset spray powder?

I would consider installing lamps at end of press (after last print unit) and after coater. The UV equipment supplier can give you the best suggestions as they have installed hundreds of units I expect.

Have you checked the Dyne level of the substrate. was it Corona treated prior to printing. Turing up the lamps may not help as 'cure' and 'adhesion' are two separate issues

Something I found during printing on plastic coated stock was that dampening solution from previous print units can have an adverse effect on subsequent print units, this is because the stock cannot absorb any excess dampening. The operators must carry as little dampening as possible and I have...

What is the stock you are printing on?

Is the issue only with one printer as you say you produce plates for many customers.

doesn't sound like you have a chronic problem so photographing every plate is mass overkill. Usually the biggest culprit is blanket/roller wash and also rubber rejuvinator. This gets on the plate usually from a blanket washing and was not dried up properly so when the press starts up the wash...

my word you must have hundreds of plates remakes to justify a camera to photo every single plate that leaves the department, dont forget some issues dont become visible till the plates are inked up. Better to spend your money on good process controls in the plateroom, Have the CTP unit checked...

Start with the basics, Do you have a Durometer guage? so you can check the hardness of your rollers. your press manual should tell you what durometer is correct for your press. Even though you dont use the press much and it sits for long periods the rollers could be getting hard and using that...

Caveman 'discovers' shadow?

highly recommend to get Auto plate loaders, Auto washup, CIP3 Ink key presetting, Sheet scanning density/spectro equipment (closed loop if possible), Temperature controlled Roller train, Auto blanket washers, these are usually standard options on most presses nowadays.

Packaging printers routinely run long runs at those speeds on cardboard. With a robust maintenance schedule the press will last for many years, that's how they were designed.

get air and jogging capability, these things are great We use a Toppy mobile jogger/Areator.

This coating 'bump' can sometimes happen when the application roller is running at a slightly different speed than the blanket.