How to reduce printing preparation time during web printing
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Web printing is as fast as 3,000 ft/min. But too long print preparation time is the biggest problem in the printing process, it will extend the life cycle of the job.
So how do you reduce the printing preparation time? In the process of sheetfed printing, we emphasize the improvement of the production process from the management, the use of people and the use of plate replacement (SMED). Here, we will explain some of the conditions in the web printing process.
Primary consideration
The primary consideration is not how long it takes to prepare for printing, but a combination of problems. The preparation time, the optimization of the entire production and the synchronization of each step of the production process must be considered. At the same time, all work preparation time, idle time and waste must be minimized. The key to successful production is to maximize production capacity while minimizing resources such as machinery and equipment.
Cost will affect consciousness
A large number of printing staff do not understand or never realize the cost of producing a print and the role it plays in controlling costs. If they do not know their position in the entire production process, then Always consider it correctly. If the manager keeps track of every aspect, all employees—from the main manager to the underlying cleaner—have a sense of responsibility to curb costs. If there is a problem during the printing process, the cause should be analyzed immediately and the machine should be shut down before the machine is wasted. Often, operators prefer to troubleshoot at low speeds.
Standardize print preparation speed
A normal print preparation requires approximately five inspection, analysis, and correction processes. The most basic problem is the printing speed problem. For example, if after five cycles, we have saved paper waste. If the press is running at 20,000 prints per hour, there will be 5,000 wastes; if we still use the same print and the speed is 10,000 iph, then the waste is 2,500, which means a 50% savings.
As the press gradually reaches its target operating speed, the ink and wetting system needs to maintain a good balance. This is the key to reducing waste... But some presses are capable of producing qualified products, but it is difficult to quickly reach full-load printing speeds from the speed of preparation - this process must be carried out slowly. There are tools, such as closed-loop inking rollers, that can be process controlled to help the operator set the ink and wetting cycle system to an optimal state; a reliable and predictive database should be developed to examine the work. Changes such as ink coverage, paper inventory, and standard weight and degree of pull required. It is also possible to preset a standard work adjustment curve as required.
Three main areas that need to be considered
Registration, color and ink issues are the three main factors in the waste of printing preparation.
Automation of the print control process is an excellent solution. For example, Berlin Industries used a closed color cycle control system with a registration control system during the printing process. The closed color loop control system increases speed and helps the press to quickly reach its desired speed through its own adjustments. This reduces paper and time waste by half. A large number of printing companies—regardless of size—do not control their inks at all. In fact, in the normal process, it is necessary to analyze the ink printing of each batch of printed matter. This requires the operator to understand what is the gray balance, how to use the density meter, and so on. If we only print in the traditional way, that is, by judging the color through the eyes - then the production process will be unstable.
Of course, human factors cannot be ignored. For example, printed operators cannot be color blind.
For web presses, with an automated folding unit, the operator can only fold the prints according to the product web in a short period of time.
The full automation of the entire operation allows the operator to print on a variety of formats with one-button control.
Utilizing advanced technology
A large number of controls are added to the press to reduce print preparation time. Examples: automated and semi-automated plate loading devices, color and color registration systems, and CIP3 preset systems. Thus, the operator's main time is concentrated on the preparation process before printing.
Adjusting the printed content during the prepress process to suit the needs of printing. If a company has very good prepress equipment, but the jobs they make are not suitable for the printing process, problems will occur during the printing process. . Therefore, the prepress production process must consider the printing process.
Regularly evaluate the work of employees
If the operators do something wrong, don't blame them. You can post their finished products on a regular basis to compare who is best. Everyone knows that when a person will do well, there will be times when they are doing bad things. We can say that only when we are good at tracking, I believe that no one wants to lag behind.
Provide employees with practical training opportunities during the apprenticeship period
Currently, operators rarely learn more during the apprenticeship. For example, a new operator needs to learn to disassemble rollers, change plates, and set up ink fountains, and be able to maneuver the machine after three months.
Eliminate the paper-feeding process
The paper-feeding process can reduce the printing preparation time. In each print preparation, the paper takes about 10 to 15 minutes, including the time to find the fasteners and find the correct hand tool to use when threading. Low-cost solutions such as studs, clips, hinges, magnets, etc. are recommended to solve the problem of threading.
Help operators increase speed
Because the current press speed is close to 3,000 feet per minute, the operator must adapt to it. When a fast press appears in a company with low productivity, it can be found that the press can't achieve such a speed, so management must be strengthened to increase speed. Once you do this, you will find that the speed of other machines has also increased. Regardless of whether the machine is old or new, the preparation time is averaged throughout the production process. Whether running at 3000 ft/min or 1000 ft/min, each job must be stopped after printing - unless the drum has an auto-erasable function. If the staff knows how to prepare for printing, they can increase their productivity.