Quality Is the key to profitability

In sublimation printing, consistency and precision are non-negotiable. When issues like ghosting or fading occur, they don’t just compromise visual quality, they represent wasted blanks, lost production time, and added costs.

While both ghosting and fading are common in sublimation workflows, they typically stem from incorrect settings, unstable substrates, or workflow flaws that are completely preventable with the right setup.

This article is designed to help you diagnose and fix these issues at the source. We’ll clarify the difference between ghosting and fading, review the most frequent causes of each, and outline the corrective steps and preventive best practices that professionals rely on to maintain consistent, high-quality output.

What Is ghosting in sublimation?

Ghosting occurs when the sublimation transfer shifts slightly during the pressing process or immediately after, creating a duplicate or blurry outline around parts of the image. It often presents as a subtle shadow or halo effect—typically in one direction—and can ruin the sharpness of text, logos, or any graphic with defined edges.

Technically, ghosting happens when sublimation dye gas reactivates due to prolonged heat exposure or movement, and deposits again in a slightly misaligned position. This results in double imaging, where the original print and the ghosted outline coexist on the substrate.

This issue is especially common when pressing large surface areas, using improperly secured transfer paper, or failing to remove the paper cleanly and immediately after pressing.

Ghosting is not to be confused with image blur caused by low resolution or ink bleed—those are different defects with different causes. Ghosting is specifically a mechanical or thermal displacement issue during the transfer phase, and understanding this distinction is key to solving it effectively.

What Causes Ghosting in Sublimation?

Ghosting is the result of unwanted movement or dye reactivation during the heat transfer process. While it may seem like a random error, it usually stems from one or more predictable causes related to workflow, materials, or equipment.

Here are the most common reasons ghosting occurs:

1. Transfer paper shift

If the transfer paper isn’t properly secured to the substrate—either with heat-resistant tape or a pressing jig—it may shift slightly when the press closes or opens. Even the smallest movement can cause the dye to redeposit in a new position.

2. Delayed paper removal

Once pressing is complete, the sublimation ink remains active for several seconds. If the paper is not peeled off immediately while the substrate is still hot, residual heat can cause the dye to continue transferring, often misaligned.

3. Incorrect pressure settings

Low or uneven pressure may allow air pockets or slight lifting of the transfer paper, creating room for micro-movements during sublimation. This is especially risky on curved or uneven substrates like mugs or coated metal panels.

4. Moisture in the substrate or paper

Excess moisture trapped in the paper or substrate can turn to steam under heat, slightly lifting the paper and creating movement. Always pre-press garments to remove humidity and use paper stored in a dry, controlled environment.

Each of these causes is preventable with consistent workflow and attention to press technique, which we’ll cover in more detail later.

What is fading in sublimation?

Fading in sublimation refers to a loss of color intensity or vibrancy in the final print, resulting in washed-out or dull images. Unlike ghosting, which is caused by image misalignment, fading is typically the result of incomplete dye transfer. Meaning the ink didn’t fully penetrate the substrate or was degraded during the process.

This issue often becomes apparent when the finished product is compared to the original digital design. Blacks appear gray, reds turn pinkish, and gradients lose depth or definition. In some cases, prints may look acceptable at first but fade quickly after washing or exposure to sunlight.

Fading is a symptom of suboptimal transfer conditions, such as insufficient heat, short dwell time, or incorrect substrate coating. It may also be caused by low-quality inks, incompatible transfer paper, or incorrect fabric content (e.g., printing on cotton instead of polyester).

Where ghosting is a spatial misregistration, fading is a color performance failure and requires a different diagnostic approach. The good news is that fading can usually be corrected by evaluating your equipment settings and ensuring proper alignment between your printer, ink, paper, and substrate.

What causes fading in sublimation?

Fading typically occurs when one or more elements in the sublimation process fail to deliver sufficient dye saturation or fixation. Understanding the root causes is essential to identifying whether the issue lies in the ink system, the heat press setup, or the substrate itself.

1. Inadequate heat or time

Sublimation requires sustained high temperatures—typically between 375°F and 400°F, for a set dwell time (usually 45–60 seconds depending on the material). Lower temperatures or shortened time can result in incomplete dye transfer, producing muted or uneven color.

2. Incorrect fabric or coating

Sublimation ink only bonds effectively with polyester fibers or specially coated surfaces. Printing on cotton or uncoated materials will produce faint, non-permanent results. Even blended fabrics with less than 65% polyester may reduce vibrancy.

3. Low-Quality or incompatible ink

Inks that are not designed for sublimation, or that have degraded due to poor storage, can cause color shifts and low saturation. Always use high-quality sublimation inks designed for your printer model.

4. Wrong or poor-quality transfer paper

Paper plays a key role in dye release. Using transfer paper not optimized for sublimation (or for your printer type) may block ink release or cause uneven absorption.

5. Substrate pre-treatment failures

Dust, oils, or moisture on the substrate’s surface can interfere with dye bonding. Always clean substrates before pressing and ensure blanks are stored properly.

By isolating these variables, most fading problems can be resolved with calibrated settings and controlled materials.

How to prevent ghosting and fading

Addressing ghosting and fading starts with identifying the weak link in your workflow. Below is a practical breakdown of how to prevent each issue using a combination of correct technique, proper materials, and equipment calibration.

Preventing ghosting

Secure the Transfer Paper Properly: Use heat-resistant tape or repositionable adhesive spray to fix the transfer paper in place, especially on hard substrates or when using swing-away presses.

Apply immediate and clean removal: Peel the paper off right after opening the press to avoid dye reactivation. Avoid hesitation or slow movements.

Ensure proper pressure: Use consistent, even pressure throughout the platen. Irregular pressure can cause partial contact and shifting.

Control moisture: Pre-press garments for 3–5 seconds to remove humidity. Store paper in a dry space and avoid humid environments in the production area.

Preventing fading

Verify time and temperature settings: Follow manufacturer recommendations for your blank and press. Use a calibrated thermometer or heat gun to validate platen accuracy.

Use polyester or coated substrates only: Ensure fabrics are at least 65% polyester and blanks are polymer-coated. Cotton and uncoated materials won’t retain sublimated dye.

Match ink and printer system: Use only genuine sublimation inks formulated for your printer model. Avoid mixing brands or using expired cartridges.

Choose high-performance transfer paper: Use sublimation-specific transfer paper that releases dye cleanly and evenly. Joto’s papers are tested for color yield and drying speed.

Prepare substrates thoroughly: Wipe off dust, oils, and fingerprints. Use lint rollers on fabrics and isopropyl alcohol on hard surfaces if needed.

By addressing these variables systematically, you’ll reduce reprints, improve customer satisfaction, and maintain consistent, high-quality results. Up next, we’ll review the tools and materials that help reinforce your print quality workflow.

Tools and materials that help ensure quality

Preventing ghosting and fading isn’t just about technique, it also depends on the quality and compatibility of the tools and consumables you use daily. Here are some essentials that help maintain consistency in sublimation printing:

1. High-quality transfer paper

Not all sublimation papers release dye evenly or dry at the same speed. A trusted option, like Paropy™ Sublimation Paper, offers reliable dye transfer, fast drying, and minimal cockling, ideal for both textiles and hard substrates.

2. Heat-resistant tape & accessories

Proper alignment starts with control. Use high-temperature tape to secure transfer paper and prevent shifting. For curved or irregular surfaces, heat gloves and mug wraps can provide added stability.

3. Calibrated heat press

An uneven or poorly calibrated press will lead to inconsistent pressure or temperature—direct contributors to ghosting and fading. Use a thermometer or heat gun to test platen accuracy regularly, and recalibrate as needed.

4. Sublimation-specific inks

Always use sublimation-certified inks from reputable sources. Substandard or incompatible inks often lead to weak saturation and long-term fading.

5. Clean, coated substrates

Choose blanks with proper polymer coating and inspect for surface contamination before pressing. Joto offers a wide selection of sublimation-ready blanks tested for durability and consistency.

Using the right tools is not just about performance—it’s about building reliability into your entire production line.

Summary: Print with confidence, not with risk

Ghosting and fading are among the most frustrating problems in sublimation printing, but they’re also among the most preventable. With a clear understanding of their causes and the right preventive measures, you can eliminate reprints, reduce material waste, and deliver consistently sharp, vibrant results.

The key is to treat every part of the process, from paper selection to heat press settings to substrate preparation, as a controlled system. Small adjustments in tape placement, pressure consistency, or substrate choice can have a major impact on your final output.

At Joto Imaging Supplies, we’ve spent decades supporting print professionals with high-performance materials, reliable transfer papers, and educational resources to help your business grow smarter, not harder.

If you’re still unsure where the issue lies in your workflow, we’re here to help. Reach out to our technical support team or explore our full collection of transfer papers, inks, and sublimation blanks built to perform at scale.

Get back to printing with confidence, and start seeing results you can count on.