Hi Paul,
Thank you for using the Xerox forum.
You have been very patient.
I agree with your following assessment that the issue seems to be Printer related if
"we reboot the printer and creo rip, we get the default test print out of the printer which has nothing to do with the rip and that is lighter too."
I would suggest that you review the following solution.
Light, Faint, or Faded Copies and Prints
If that does not help identify or resolve your issue I would consider contacting technical support at the following link and request that the issue be escalated. Fast Track to the Expert