How to ensure that cigarette packages are homogenous, uniform and stable?
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With the implementation of the standardized bidding mechanism of tobacco enterprises and the implementation of sunshine procurement, each brand of cigarette packets must be provided by two or more cigarette package printing enterprises, but the number of suppliers increases due to the packaging materials and processing techniques used. Different, there are certain differences in the suitability of the package of cigarette packets, coupled with a wide variety of cigarette packaging equipment, how to ensure the homogenization, uniformity and stability of cigarette packages, to adapt to the normal processing of different cigarette packaging equipment, is pendulum The biggest issue in front of cigarette pack printing companies. The author has been engaged in the research of cigarette package printing technology for many years. Here I would like to talk about some ideas and suggestions for the homogenization process of cigarette package products.
Industry Status
Through the visits to tobacco companies, we found that the same products produced by different cigarette package printing companies have certain differences in the suitability of the upper machine packaging, resulting in card machine, scratches, planting, not folding, or not. Temperature resistance, non-wear resistance, degumming, etc. The same product produced by the same cigarette package printing enterprise has different differences in the suitability of the upper machine because of different paper origins and different ink manufacturers. Although the packaging performance on the medium speed packaging machine is stable, there are different degrees on the high speed packaging machine. Card machine and other phenomena. All of the above have affected product quality and machine production efficiency, and increased the labor intensity of frontline employees.
1. Applicability of the packaging of different cigarette package printing products
Check the suitability of the same product produced by the five cigarette pack printing enterprises on the high-speed packaging machine, and there are packaging failures in different situations. Looking back at the product samples of each cigarette package printing company, the results show that there is a certain difference in the adaptability of the upper machine packaging.
2. The current status of the suitability of the products on the same cigarette pack printing enterprise
Check the suitability of the same product (provided by five paper mills) of different papers of the same cigarette printing company. Check the product samples and test the physical properties of the papers of the five paper mills. The results show that there are some differences in physical properties.
Solutions
The homogenization and homogenization of cigarette packets is the primary problem faced by large-scale cigarette package printing enterprises. The current general treatment method is to assign professional technicians to the tobacco companies to implement on-site tracking services, and carry out specific analysis for specific problems. Problems with process and material improvements. However, due to the diversity of product materials, the differences in processing equipment and environment, and the uneven quality of personnel, the quality of products has not been fundamentally improved, and there are problems of headaches and pains. In order to prevent the problem from recurring, the cigarette package printing enterprise can only realize the homogenization of the product by starting from the standardization and implementing the whole process and all-factor prevention and control.
1. Establish a full-process cigarette pack technical standard
There are many kinds of cigarette processing materials and complex categories. From the existing materials and products, the apparent requirements, physical properties, printing suitability and suitability of the upper packaging, the technical standards of cigarette packs are roughly divided into four categories: Appearance requirements. , physical requirements, suitability requirements for the machine, safety and health requirements. After long-term practice research, our company summarized the main indicators affecting the quality of cigarette packages.
The formulation of standards is not simply copying national standards, industry standards, and tobacco enterprise standards. It should be based on the actual production needs of tobacco companies and cigarette printing enterprises, and the technical level of upstream material manufacturers as the foothold, processing materials and regions for the same products. System analysis of conditions, process flow, equipment level, etc., field research on various differences, after system testing, proofing, small test, pilot test, batch test multiple test, tobacco factory packaging experiment, using big data analysis, exploring Outsource inspection index parameters, process parameters, control process parameters and key control points of the same product under different production conditions to ensure quality consistency, scientific and reasonable preparation of technical standards. Table 5 is the technical requirements for the suitability of our company to participate in the suitability of the cigarette packs on the packaging of the Chinese cigarette company.
2. Implement the whole process of data control
(1) Processing parameters of curing equipment
To achieve the homogenization of the same product under different materials, it is necessary to grasp the pain points of key equipment in important processes. Through process verification and testing, the equipment parameters are adjusted in a targeted manner, focusing on refining the processing parameters and determining different materials in the same process. The processing parameters are solidified, and standardized operation, inspection and maintenance are carried out to achieve the interface between the operator and the technical standard. The production process is strictly in accordance with the technical standards. In order to meet the requirements of the acceptance criteria for tobacco enterprises, the company has established a homogenization process research project group, selects the paper and ink of each supplier for proofing, and sends them to the tobacco companies for small test, pilot test and batch test. In this process, the project team adjusts the processing parameters of the equipment for key equipment such as printing equipment and molding equipment, and sets corresponding processing parameters for different materials.
(2) Data control of the process
Test instruments equipped with required control items, carry out various types of indicators detection and data comparison to ensure the stability, reliability and scientificity of the test data. Establish offline and online detection systems, take good entrances and processes, take prevention as the mainstay, use detection methods and scientific analysis methods, perform mathematical and statistical analysis on product inspection data, master the fluctuation of product quality, and build on database. Strengthen the use of mathematical statistics technology and accurately grasp the status quo of quality.
Occasionally hold product quality analysis meetings, propose improvements, implement PDCA cycles, and prevent differences in materials and other factors. Promote the stratified and grading quality early warning, implement the monitoring and management of the whole process of logistics, realize the transition from control indicators to control parameters, change from result control to process control, and change from manual control experience decision to automatic control scientific decision.
In order to achieve the control of data, our company has established a standardized testing laboratory, which has passed the national laboratory accreditation to ensure the accuracy of the material inlet inspection data. Secondly, it has adopted the original high-volume automatic production line of roll-to-roll. The printing processing method has established a full-line online detection device for product quality, and the combination of single process inspection and control and online full-scale inspection and control has realized the online accurate detection of the whole process, and the orderly linkage in the regulation.
3. Process operation standardization
(1) Standardization of inspection operations
Different cigarette package printing enterprises have different data detection due to different time of purchase equipment, production unit, operating environment and personnel quality. In order to ensure that the test data is fair, rigorous, scientific and accurate, it is necessary to use standardized work instructions as the yardstick. Under the environmental conditions stipulated by the standard, the project test should be carried out according to the standard. The instrument calibration and data comparison should be carried out regularly, and the operation and responsibility of the operators should be carried out. Awareness training, standardization of testing.
Our company has implemented the laboratory ISO/IEC17025 system certification for testing, and has reviewed the laboratory hardware, software, and employee testing capabilities. To this end, the level of inspection by operators has been greatly improved.
(2) Standardization of production operations
2.1 operation standardization
Standardize the production process of the printing plate; standardize the cleaning procedure of the plate, plate hole and plate axis after the printing plate is used, and formulate a perfect cleaning procedure to reduce the probability of blocking, poor overprinting accuracy and ink smear when used twice.
2.2 paper operation standardization
Standardize the storage and storage period of paper, use it according to the principle of first-in-first-out, and use it in the same time period of the same batch and same color.
2.3 ink operation standardization
Establish color matching database of different types of papers, according to the status quo of different types of papers and different hue of different manufacturers, according to the batch hue data of paper storage inspection, allocate reasonable ink ratio parameters to make multiple gravure printing machines produce various materials. A product of the same hue to achieve homogenization of the tobacco product.
(3) Detection and rejection automation
Product quality is produced, not tested. In today's high-speed production, offline testing with experience and human eyes can no longer meet the needs of modern production. In order to ensure uniform and stable product quality, our company has developed and configured a large-width, high-speed, multi-channel die-cut connection detection and automatic rejection system to ensure the accurate rejection of waste products, and successfully realized the web-cutting machine finished products online. The high degree of automation of inspection and rejection meets the company's requirements for product quality and productivity.
At this stage, it is the deep-water period of the transformation and development of printing enterprises. How to promote the development of China's printing enterprises to “green, digital, intelligent and integrated” during the “Thirteenth Five-Year Plan” period, focusing on the traditional orientation of green, safety, energy saving and high-tech transformation Technical research, management innovation based on lean and efficient orientation is the top priority of all major printing companies. Only by continuously improving the core competitiveness of enterprises, meeting the needs of market-oriented reforms, and benefiting from brand and quality, enterprises can Today's market-oriented reforms are invincible. Carrying out the homogenization process research of tobacco package products is the pain point and difficulty of mass production of tobacco single products at the present stage. It is the way to improve the quality and efficiency of cigarette package printing enterprises. Only the cigarette package printing enterprises can grasp the pulse of market and production. In the market-oriented reforms, the wind and the waves are broken.