I have a slightly different problem than any of the other printer/spooler related that I've been able to read about online.
We have a Windows 7 Home computer with two printers on it, both are USB connected. The laser works fine and never has any issues. Our card printer continually gets jobs stuck in the spooler. The problem started every now and then and now it does it about every other print attempt. In each case we have to stop the spooler service and delete the spooled files to clear it. I gave them a script to do that for them, but it is still a royal pain. They have to run that script and sometimes power cycle the printer to get things back to working again. We have even tried to bypass the spooler and print directly to the device, but it keeps resetting itself back to using the spooler and it clogs up again.
I've ran SFC and there are no problems. We have used a different card printer and it has the same problem. There are no errors related in the event logs. I have updated the firmware and drivers for the printers and uninstalled/reinstalled them more than once. The OS is fully patched and updated for both critical and optional items. We have tried different cables as well.
We know how to clear the issue, but that it keeps happening several times a day without any real idea of how to stop it is a real problem. This unit is in a customer area and redoing the OS will be a huge pain if that is the only solution. Any other ideas on how to prevent it?