You're printing away when you notice an unusual smell. Is this normal? Is something wrong? Should you call someone? The answer depends on what kind of smell and when it occurs.

Normal Printer Smells

First, let's establish what's expected:

New printer smell: A mild chemical or plastic smell from new printers is normal. It's outgassing from manufacturing processes and should fade within days to weeks.

Laser printer toner smell: During printing, the fuser heats to around 200°C to melt toner onto paper. A slight warm, dry smell is normal during heavy printing.

Ozone smell: Some laser printers produce trace ozone as a byproduct of the corona wire charging process. It smells slightly sharp or metallic. Small amounts are normal; strong ozone smell indicates the ozone filter needs replacement.

Concerning Smells: Take Action

Burning plastic or rubber:

This is NOT normal. Stop printing immediately and power off the printer.

Possible causes:

  • Foreign object inside the printer touching the fuser
  • Melting plastic component
  • Failing fuser rollers
  • Overheating electronics

Electrical burning smell:

A sharp, acrid smell similar to burning wires. Power off immediately. This indicates potential electrical component failure – circuit boards, power supply, or motor windings.

Overheated metal smell:

If the printer has been running excessively long or is overheating due to blocked ventilation, metal components may overheat. Improve ventilation and let the printer cool.

Immediate Steps for Concerning Smells

  1. Stop printing and power off. Unplug the printer if you can do so safely.
  2. Do not open the printer immediately. Internal components may be extremely hot. Wait at least 15 minutes.
  3. Ensure ventilation. Open windows if the smell is strong.
  4. Inspect after cooling. Look for visible damage, melted plastic, or foreign objects.
  5. Do not use the printer again until the cause is identified and resolved.

Common Causes and Solutions

Paper jam burning on fuser:

Paper stuck on the hot fuser can burn, creating smoke and smell. Clear jams promptly. If paper has burned onto fuser rollers, professional cleaning or fuser replacement may be needed.

Labels or adhesive residue:

Never run adhesive labels through a laser printer unless they're specifically rated for laser use. Adhesive melts and contaminates the fuser. This usually requires professional service.

Overworked printer:

Printing beyond the duty cycle causes excessive heat. Let the printer cool, and if it happens regularly, you need a higher-capacity device.

Poor quality toner:

Cheap compatible toner may not be formulated for your fuser temperature. It can produce smell or even damage components. Switch to quality toner.

Blocked ventilation:

Printers need airflow. If vents are blocked by paper stacks, walls, or accumulated dust, overheating occurs. Relocate the printer or clear obstructions.

Fuser-Related Smells

Many smells trace to the fuser unit. This component operates at high temperatures and wears over time:

New fuser smell: A freshly installed fuser may smell slightly during the first few hundred pages as coatings cure. This is normal and temporary.

Failing fuser smell: As fusers age, the heat rollers degrade. A persistent smell during regular printing suggests the fuser needs replacement.

Fire Safety Considerations

While actual printer fires are rare, they can occur. Practice basic safety:

  • Never leave printers running unattended overnight
  • Have a fire extinguisher accessible
  • Know your building's fire procedures
  • If you see smoke or flames, evacuate and call emergency services

Professional Assessment

If your printer has produced concerning smells, have it inspected before using it again. Internal damage may exist even if the printer seems to work normally afterward.

At ilexDigital, we diagnose printer problems including damage from overheating incidents. We'll inspect all components and advise whether repair is feasible or replacement is necessary. Contact us for urgent assessment of printers with burning smells.