Full waste die cutting application experience
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In recent years, with the rising cost of manpower, raw and auxiliary materials, and the increasingly prominent problems such as hard work and hardship, people from all walks of life are facing enormous challenges, and the packaging and printing industry is no exception. It has become a common consensus for everyone to use automation, information technology and intelligent means to improve the production process and seek industrial upgrading.
In order to promote the process of “machine generation” and “smart printing factory”, our company has been introducing automation equipment for many years, replacing equipment by equipment and improving the automation degree of equipment, which has significantly improved the company's production efficiency and product quality. In the forefront of the industry in the introduction of new equipment and technological innovation.
In the die-cutting process, our company introduced a full-disposal die-cutting machine in 2015 and 2016. In the application process, through the continuous optimization of equipment and technology, the advantages of the full-clear die-cutting technology were fully utilized. Improve the production efficiency, production capacity and product quality of our company's die-cutting process.
In this paper, the author will analyze the existing problems, advantages and optimization process of the application of the whole waste-cutting die-cutting technology in the field of drug packaging, hoping to learn from and help the peers.
01. introduction background
In the first half of 2015, our company's business increased greatly. Compared with the same period of last year, the die-cutting output increased by 20%, far exceeding the existing die-cutting capacity, so it could not be delivered in time, and the production pressure was huge. At that time, our company had 7 die-cutting machines, but it was generally “aged”. Among them, 5 die-cutting machines that have been in operation for more than 10 years (two have been in operation for 15 years), the equipment accuracy and condition are poor, and it is no longer possible. Production in the peak season requires the purchase of new equipment to increase production capacity. In addition, due to the labor intensity of the stripping process, there is a difficulty in recruiting workers and making it difficult for people to stay. When the production waste is insufficient in the peak season, all non-production personnel turn to the workshop to scrap the goods three days a week, which has adversely affected the normal production and operation. It is urgent to increase the die-cutting equipment and improve the automation of the equipment.
The all-clearing die-cutting machine can use the clean-cleaning station to remove the waste edge of the paper, and collect the intact box, eliminating the original manual tearing and scrapping process, which is not only efficient but also caused by manual waste. The tearing, tearing, etc. are avoided and the quality of the product is improved. The introduction of a full-clearing die-cutting machine not only improves the die-cutting capacity, eases the pressure of manual waste-cutting, but also conforms to the development ideas of our company's “machine-generation” plan and “smart printing factory” construction. To this end, our company, as the first person to eat crabs in the field of drug packaging printing, took the lead in introducing a full-clearing die-cutting machine, and since then it has moved to the era of all-disinfection die-cutting after drug packaging.
02. Existing problems and advantages
As we all know, the full-cutting die-cutting machine has been the first in the field of cigarette packets since its inception. Many die-cutting equipment manufacturers have tailored them to meet the requirements of “exquisite appearance, complicated process and strict quality control”. A complete decontamination process plan, including the design of the equipment itself, the technical parameters of the box, etc. It can be said that in China, the full-discarding die-cutting machine is born for cigarette packets.
In recent years, due to the soaring labor costs and other factors, drug packaging printing companies have begun to pay attention to the full-clearing die-cutting machine. Although the application of the whole-cleaning die-cutting machine in the field of cigarette packets is very mature and stable, the characteristics of cigarette packets and drug packs are different. Whether it can be well integrated into the production of pharmaceutical packages, many drug package printing companies are waiting to see. Then, in what areas is the application of the whole dishwashing die cutting technology in the field of drug packs?
1. The package order is small
In general, cigarette pack orders are large in volume, and a single order is usually produced continuously for several days or even longer. The large-volume products can fully utilize the advantages of the full-clearing die-cutting machine. The order of the drug packs is small. In our company, for example, there are nearly one thousand orders per month. The production volume of each order is generally 15,000 to 17,000 sheets, and each shift needs to be replaced with 3 to 4 orders. Orders are far from each other, and frequent replacement orders greatly reduce the efficiency of the full-clearing die-cutting machine.
2. There are many types of drug packs
As we all know, the types of cigarette packs are basically the same, but the types of packs are various. Some of them look basically the same, but the actual measurement is 1~2mm. Therefore, under normal circumstances, the number of die-cut editions of a large-scale pharmaceutical package printing enterprise is 1000-2000 pieces or more.
For the full-clearing die-cutting machine, in addition to the high price of the equipment itself, the biggest cost investment is the box-splitting device, and the price of each box-boxing device is tens of thousands of yuan, because the types of medicine-packing boxes are various, It is impossible to prepare a set of bins for each product. Only some products with large orders can be selected for full decontamination. Even so, to meet the use of a full-disposal die-cutting machine, 40 to 50 sets should be prepared. Box splitter.
Therefore, due to the wide variety and non-standard types of drug packs, not only the production efficiency is reduced, the production cost is increased, and more importantly, it is also a serious waste of social resources.
3. The asymmetric side of the waste paper
Figure 1 shows the side of a conventional cigarette packet waste paper, and Figure 2 shows the side of a conventional package waste paper. Through the comparison of the two pictures, we can find that the waste paper side of the medicine package is much more complicated than the waste paper side of the cigarette pack. Due to the irregularity and complexity of the waste paper of the medicine package, the production of the whole waste paper cutting machine is seriously affected. effectiveness.
However, because the combination mode of the drug pack is different from that of the cigarette pack, there is still a difference in the process of the whole waste disposal process. In comparison, it is easier to clear the package. The complete waste recycling process of the cigarette package is: first die-cutting, then clearing the hole position and the trailing edge in the semi-cleaning unit, and finally clearing the box in the full-cleaning unit. The layout method of most drug packs, except for the box, all the waste paper edges are connected together. The complete stripping process of the drug pack of this joint mode can be directly after the die-cutting. The unit clears the box and saves the middle half-discarding link. Of course, according to the different way of the joint version, the whole waste disposal process of some medicine packs will be the same as the cigarette pack.
03. optimization process
Although the application of the full-cutting die-cutting technology in the field of drug packaging has some "gap" that cannot be crossed, it can not stop the heart of the drug packaging printing enterprise. Since the introduction of the full-clearing die-cutting machine, our company has been continuously optimizing to give full play to the full advantage of the full-cutting die-cutting technology.
1. Optimization of non-stop sampling function
The all-clearing die-cutting machine introduced by our company in 2016 is a new-generation model launched by Tianjin Changrong Printing Equipment Co., Ltd. (hereinafter referred to as “Changrong Shares”) in 2014. This model is all in addition to the well-known In addition to the full function of the waste die-cutting machine, it is also possible to perform sampling without stopping the machine at full speed. The birth of this technology and equipment has completely solved the problem that the efficiency and quality control of the traditional all-clearing die-cutting machine cannot be combined.
But the birth of new technology has also brought new technical problems. When the equipment realizes non-stop sampling at high speed, it is necessary to add a buffer device to reduce the inertia of the sample. The smooth falling of the waste paper also requires a buffer device, and the buffer device usually adopts a brush. However, when the equipment is running at a high speed (7500-8000 sheets/hour), the shape of the waste paper side of the medicine package is complicated, and the brush is easy to hang on the side of the waste paper, so that the waste paper side cannot fall or be skewed, which may cause the equipment. The machine stops working, so the equipment can only work at speeds of 5,000 to 6,000 sheets per hour, and the maximum efficiency cannot be achieved.
To this end, our company and Evergreen Co., Ltd. jointly set up a technical research team to optimize the devices such as cushioning brushes and waste paper side belts. After more than two months of joint efforts, we finally broke through the technical difficulties. Stable production for a long time at full speed.
2. Optimization of connection point design
For the connection point, whether it is a medicine bag or a cigarette packet, there is a common feature that the connection point cannot be exposed outside after molding, so generally follow the following principles: First, the connection point is opened in a relatively hidden position; second, the number of connection points The less the better, the third is to ensure the strength of the connection point; the fourth is that the connection point is relatively fixed on each box.
The position distribution and quantity of the connection points will affect the fluency of the whole waste. As can be seen from Fig. 5 and Fig. 6, the number of cigarettes is more connected, and more importantly, the distribution is even, and it will be more stable under high-speed operation. And the number of connection points of the drug pack is less. Then, in the case of a small number of connection points and uneven distribution, how to meet the requirements of high-speed operation? In addition to following the above principles, there are the following precautions:
(1) Depending on the thickness of the paper, the width and depth of the joint should be adjusted accordingly;
(2) The width of the connection point in the paper feed direction is 0.1 to 0.2 mm larger, and the firmness of the connection point in the paper feed direction is enhanced;
(3) The shape of the joint should be "U" instead of "V".
3. Optimization of the box
The sorting box is a very important part of the full stripping die cutting machine. The optimization of the sorting box is mainly reflected in the elimination of the following three problems and faults.
(1) Soft guide strips are prone to wear
As shown in Figure 7, the soft guide strip is a thin film that is itself a consumable item. The soft guide strips are generally used in the lower part of the single-blade steel strip, because for the cassette, there is almost no gap at the single-blade, so it is impossible to use a guide strip with a stronger or too thick thickness, which would otherwise damage the cassette.
Although soft guide strips are consumables, some measures can be taken to extend their useful life. First, the grooved lower edge of the suspension flexible guide strip is treated so that the thickness of the lower edge is smaller than the thickness of the single-blade steel strip, and then the lower edge of the groove is polished into an arc shape, which reduces the soft guide strip. Friction, which increases its service life.
(2) The box is not collected neatly
The reason why the pieces are not collected neatly is generally that the outline size of the lower box is too large or the position of the side slider (see FIG. 7) is deviated, which causes the piece to fall freely when it falls, and cannot guide the accurate positioning of the piece. Optimization measures: First, check whether the contour size of the lower box is too large, reduce the contour size according to the actual situation, and try to use the one-time processing and forming the box to prevent the box from being damaged due to the heat deformation of the steel during the welding process. The contour size is deviated; secondly, it is checked whether the side slider moves up and down smoothly, and only the side slider that moves smoothly up and down can ensure accurate positioning of the drop.
(3) Scratches on the side of the box
The reason for the scratch on the side of the box is that the lower single-bar steel strip is too wide or the curved steel strip (see Figure 7) is not round enough, and the disc is blocked when it falls to produce a scratch. Optimization measures: If the box type arrangement allows, the thickness of the single-bar steel strip should be reduced as much as possible, but it should not be excessively reduced, so as not to affect the strength and service life of the box. If the curved steel strip is not smooth enough, use oil stone or sandpaper for proper grinding.
In summary, although there are still some problems in the current promotion of the full-disposal die-cutting machine in the field of pharmaceutical packaging, with the improvement of the requirements for production automation and the promotion of the construction of “smart factory”, The waste die cutting technology will be further popularized and become the mainstream of future die-cutting production.