Application case of data in the printing process
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In the printing process, we often face such problems. The same printed products, the same equipment, and the same environment produce different printing results, hue, and friction resistance in many different printing times. The indicators have fluctuated, but they can't find the root of the problem. Is the substrate, ink, equipment, operator, printing environment, etc. the same, and there is really no change in the factors? The following two cases will help We answer this question.
Offset printing statistics application case
The two products are printed in the same product. The paper and ink used are the same brand. The results in the comparison table show that the consumption of yellow ink is abnormal. The practical quantity of yellow ink in Table 2 is 1.7kg higher than that in Table 1. Moreover, the single product of Table 2 is indeed due to the poor drying of the yellow ink, which causes the printing time to expire. As the consumption of yellow ink unit increases, the amount of ink and water in the printing process rises too high, which in turn causes excessive emulsification of the yellow ink during printing, so a long drying time is required. After identifying the problem, immediately investigate the ink used at the time, and further investigate, and found that the batch of yellow ink used in the two printing processes is similar, but the color saturation of the batch of yellow ink used in the second printing is the first time. There is a certain gap in the batch used for printing, which has caused the ink volume to be increased during the printing process to meet the requirements of the sample ink color. After finding the cause of the problem, the hidden dangers of the problem were eliminated in time, and no such problems occurred during the subsequent printing process.
Gravure printing statistics application case
After the pure aluminum foil gravure is replaced with the water-based gravure ink, the die-cutting unit always has the phenomenon that the die-cut quality of the same product is high or low. What is the cause? Because there is no difference in the color of the printed product, We only checked the various processes before printing to die cutting (Fig. 1), and found that all the embossing thickness of the products meet the requirements and the products after the breakage did not have the problem of unevenness. There are no fluctuations in the indicators. What is the cause of such problems? We have compared the products with relatively good die-cutting effect with the products with poor die-cutting effect, and checked all kinds of records one by one. It was found that there was still a problem in ink consumption, and the ink unit consumption was as shown in Table 3 and Table 4.
Comparing the data listed in the table, the unit consumption of white ink and yellow ink showed large fluctuations. The consumption of white ink and yellow ink in Table 4 was much smaller than that of Table 3. Since the printed product adopts the design of the upper half of the full version of the white ink and the lower half of the gold rim, the die cutter will be in contact with the white ink of the printed surface and the yellow ink, and the die cut layer will be relatively thin in the die cutting process. When thick, it will alleviate the die-cutting resistance of the tool on the surface of the print to reduce the wear of the tool; on the contrary, when the ink layer is thin, the wear of the tool will be accelerated, so the tool wear is lighter under the conditions of Table 3. It is the reason why the die-cut effect of the order of Table 3 is better than the order of Table 4. After finding the cause of the problem, we continued to investigate and found that there was a certain lack of tracking of the gravure printing plate. The printing plate printing durability was not well controlled. When the printing plate was worn out, it was still used. The replacement of the printing plate is often carried out by experience. When the color depth of the printed product is significantly different, it is replaced. However, the thickness of the ink layer on the surface of the printed product has been greatly reduced, which will naturally affect the subsequent die cutting. effect. After discovering the root cause of the problem, we decisively improved the construction of the corresponding rules and regulations, and standardized the use and tracking of the printing plate. Since then, the die-cutting effect has improved to some extent.
Through the analysis of the above two different cases, we found that, in fact, at the time of the problem, although there are no abnormalities in the indicators, the intrinsic influence factors have undergone subtle changes; although they are not perceived by us in the process, But there have been big changes in the final results. This change can affect all aspects of product quality, production efficiency, etc., so don't ignore the fluctuation of any data around you. When the data shows large fluctuations, it is likely to cause various problems. This requires us not to ignore the statistics and analysis of various types of data in daily production, because these data will guide you to discover hidden dangers in many production processes and help you solve problems to ensure the normal production.