My opinion on the transformation of packaging printing to green production process
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China is a world's most populous country, and of course it has become a big country in packaging and printing. However, since the financial crisis of 2008, printing enterprises in many places in China have continued to show a decreasing trend. The total number of small and medium-sized printing enterprises in the “Yangtze River Delta” and “Pearl River Delta” economic zone cities is almost every year. The printing company closed down. The reason is that in addition to the market downturn, the supply and demand of printing business is seriously unbalanced. There is another important reason. That is because the core competitiveness of printing companies is increasingly unable to meet the requirements of market development. Among them, there are many factors in production mode, production process lag, and poor material performance, resulting in low production efficiency and product quality, high production and energy consumption, high production costs, and the existence of this phenomenon is contrary to the country. Policies and goals for low carbon economy, green production and environmental protection. Therefore, the current printing industry can only enhance the ability of enterprises to control the market if they follow the law of market development and change to the green printing production mode.
1. Correct understanding and understanding of the green production process of packaging and printing
Green represents vitality and vitality, green symbolizes strong vitality, green is the most common color in nature, and green is also a symbol of hope. Perhaps because of this, green has become the representative color of the International Association of Environmental Protection Organizations. I think green is synonymous with environmental protection, health, hygiene, pollution-free, energy-saving and material saving. Then, according to the author's understanding and understanding, the green production of packaging and printing technology should be the use of new technologies, new equipment, new materials, new processes, new methods and new management methods and means to achieve better use and saving of raw materials. Reduce production materials and energy consumption, promote the simultaneous improvement of production efficiency and product quality, and protect the ecological environment and reduce environmental pollution, and better protect the health of the human body. In this sense, the green production process of packaging and printing is a systematic project, which involves a wide range of aspects, including not only technological innovation, transformation and rational design of equipment, plant and related facilities, but also paper, ink and glazing. Improvement and expansion of performance and adaptability of printing consumables such as oil, car wash water, blankets, rubber rollers, fountain solutions and additives. In addition, applying scientific methods and management methods, technological innovation and transformation of traditional methods of operation and production processes, to achieve the purpose of reducing production costs, improving production efficiency and product quality, is also an important way to achieve green printing technology. Therefore, packaging and printing enterprises are shifting to the green production process. The most important thing is to change the concept of production management and production management, and change the traditional backward production methods and processes. For example, equipment that needs to be preheated during production and needs to be washed. , it is best to arrange in the form of continuous work. There are also high-energy-consuming equipment that can be used to avoid the peak period of electricity production, which can better realize the rational use of energy and reduce production costs.
2. Green production through scientific and rational design
In the years of work practice, the author found that scientifically and rationally designing the printing layout can not only reduce the fearless waste of the production materials, but also improve the production efficiency and product quality. For example, some color printing products only need to output 2 or 3 plates according to spot color printing. If you press four-color plate, you have to output 4 plates, the layout of the flat net structure, and several kinds of printed colors. The color is equivalent to the effect of several spot colors, and the printed layout of the color is most prone to quality defects such as bar marks, spots and chromatic aberrations, and the rate of unqualified products is also high. Therefore, for multi-color overprinted layouts, if the effect of coloring is the effect of spot color, it is best to plate and print according to the spot color, which can save the plate material and facilitate the control of printing quality. For another example, if the printing material is thin and soft, the precision of the printing machine is not high, and the customer designs the layout of the printed product into a precise overprinting structure. In this regard, it is necessary to consider designing the overprinted layout as a trapping structure, that is, The light-colored layout outline is appropriately enlarged or reduced in a small amount, so that if the overprinting is not accurate, the edge of the dark layout is less likely to appear whitening defects, and the rate of defective printing will be better controlled. In addition, the printing products using the flexographic printing process should take into account the softness of the flexographic plate and the tendency to be deformed during the imprinting process. From the technical point of view of improving the definition of the printing plate, the printing plate should avoid designing small lines, Text or pattern, so as to avoid the printing loss caused by the quality problems such as paste and dirty. When designing, the text and line layout can be designed to be larger, which can make the visual sense of appearance, improve the use effect of the product, and better guarantee the printing quality of the product.
3. Pay attention to choosing the right raw materials
① Choose the right paper and the right printing process. Paper is the main component of packaging printing production costs. The difference in paper types and quality grades is the main factor affecting production consumption and quality of products. Reasonable selection of the appropriate paper type and quality according to the use of the product is an important measure to achieve rational use of valuable natural resources. Therefore, according to the price and complexity of the goods, as well as the characteristics of the goods and the basic requirements of packaging protection, it is a crucial control link to select the appropriate paper type and quality level for printing production. The author believes that it is necessary to improve the packaging quality effect of the original paper through reasonable adjustment and control of the process technology to avoid waste of resources caused by excessive packaging and luxury packaging. In addition, according to the characteristics of the base paper, the corresponding process can be selected to better improve the printing quality of the product. For example, if the paper or paperboard with bright surface and poor gloss performance is printed on a relatively large amount of ink, if the offset printing process is used for printing, the quality effect will be unsatisfactory, and depending on the number of printing and the structural characteristics of the layout, Printing by flexo, gravure or silk screen printing, the quality effect will be better balanced, and the non-conforming products will be greatly reduced.
② Choose environmentally friendly inks for printing. Ink is one of the main materials that affect the printing quality and production consumption of products. From the environmental protection and sustainable development of the production process, the ink should be non-toxic, odorless, free of lead, chromium, cadmium, mercury, arsenic, antimony, Harmful substances such as fluorescent substances, and other harmful solvents, etc. Therefore, it is a social responsibility of printing companies to select inks that do not contain harmful substances or harmful substances below the relevant standards. Especially for printing products involving food packaging, it is necessary to use environmentally friendly inks for printing. Since the water-based ink is water and ethanol, it is a non-toxic solvent, and the safety relative coefficient is high, so that the packaging can be better avoided. The ink on the stain contaminates the food by migration or the like. Therefore, the gravure or flexo printing process should select environmentally friendly water-based ink for printing. The embossing and offset printing can also be printed with U V ink, which has a fast drying speed and can avoid the pollution problem caused by the use of dusting and anti-sticking. In addition, the offset printing process can also be printed with soybean environmentally friendly inks, because it uses soybean oil to replace the mineral oil in the ink, and the soy oil-based ink made by the company replaces the ordinary petroleum-based ink, which can better avoid the pollution of the product.
4. Energy saving and consumption reduction through technical transformation of equipment
① The replacement of the single-sided corrugating roller saves energy and reduces consumption. Corrugated rolls are an important part of the production of packaging products. The high height of corrugated board and the number of turns in the unit of 30 c m length and the waveform characteristics of corrugated board are important conditions that affect the strength of corrugated board. The structural characteristics of corrugated board also determine the corrugated paper rate for length units. The competition in the carton industry requires the production of quality-compliant cartons on the most economical basis. The author's effect on the transformation process of a corrugated roller in the past is still fresh in memory. The tooth of a single-faced corrugating roller is damaged badly. When making a new corrugating roller, the corrugating roller is directly customized as: 4 8 teeth / 30 cm; the height of the roller roller is 2. 9 mm, which is larger than the original one. The number of molars is 4 teeth, and the height of the molars is reduced by 0.2 to 0.3 mm, but it is still within the standard range. In this way, the single-faced corrugated unit is subjected to process test analysis under the same production process, environment and paper quality conditions. The results show that the corrugated board produced by the machine before the transformation has more corrugated paper, but its quality is Not as good as corrugated paper with a small amount of paper on the corrugated layer. That is, the original 2 m long corrugated paper can only form 1. 3 8 5 m long corrugated cardboard, and the 2 m corrugated paper after the roll change can form 1. 0 5 5 m long corrugated cardboard. After many tests and comparisons, the edge pressure strength, bond strength and plane compressive strength of the corrugated board produced after the machine transformation are higher than before the transformation, not only achieving the production purpose of energy saving and consumption reduction, but also the quality of the product. Can meet the requirements.
② The guide dog type single-face machine was transformed into a vacuum adsorption structure. The guide plate of the old-fashioned single-sided machine, after being used to a certain extent, will have a large wear phenomenon, so that the corrugated paper can not be accurately positioned on the lower corrugating roller for coating and molding. In addition, the applicator roller tends to accumulate adhesive on both sides of the guide plate, all of which will affect the uniform molding quality of the gluing and corrugating, which is prone to poor adhesion quality and high raw material consumption. The corrugated cardboard formed by vacuum adsorption positioning can better eliminate the positioning instability caused by the mechanical wear of the claw-type structure, and make the machine easier to achieve normal high-speed operation. The guide type single-face machine is transformed into a cover-type vacuum adsorption mode, which can effectively ensure the processing quality of the corrugated board and reduce the consumption of the corrugated forming process. The cover type vacuum adsorption device also has a significant advantage in that continuous and stable high-speed operation can be achieved when the production paper web is small.
③ Use a heat-conducting oil furnace instead of a steam boiler to achieve energy saving. Energy is a prominent factor affecting the production cost of carton. The heat transfer oil furnace can obtain a higher working temperature at a lower operating pressure. The heating temperature is generally between 250 ° C and 3 2 0 ° C, which can satisfy the carton. Production requirements. Its main advantages are: Thermal efficiency is maintained at an optimum level over a wide load range, enabling stable heating and precise temperatures. Due to the small temperature error of the heat transfer oil furnace outlet and reliable operation control and safety monitoring device, energy saving and consumption reduction can be achieved. Therefore, the use of a heat-conducting oil furnace to replace the traditional steam boiler is also a direction for the transformation of a production mode that can be considered for packaging and printing enterprises to achieve energy saving and consumption reduction.
④ Save energy and reduce consumption by adding steam and condensate recovery system. The carton production line can be equipped with steam and condensate recovery system to pressurize the condensed water and waste steam generated by the production line by the principle of piston cylinder compression, and directly press the water vapor mixture into the boiler to make the boiler steam point and The steam recovery machine forms a closed circulation system for maximum energy savings. This steam recovery compressor uses a new material that is resistant to high temperatures and wear and has oil-free wear resistance. The steam recovery machine is directly recovered by high temperature method, and the thermal efficiency is up to 60%, and the steam trap of the steam equipment can be eliminated. The steam recovery compressor is driven by a mechanical transmission system to pressurize the high-temperature steam-water mixture to reach and exceed the pressure during operation of the boiler, and press it into the drum for recycling to save soft water and save electricity and coal energy. .
5. Reasonable use of large format printing to reduce production costs
In fact, according to the characteristics of packaging and printing products, the advantages of large-format printing machines are also the choice of green printing. Some printing factories believe that large-format printing machines are used to print long-line printing products without considering the structure of the products. The result is counterproductive, not only does not improve production efficiency and product quality, but also greatly increases production consumption. Therefore, large format printers are best suited for printing carton products and other large format printing products. If you do not consider the characteristics and structure of the product, and only consider the large amount of printing, you will need to cut the small size carton, paper bag or other small-size trademarks that need to be cut and die-cut, as well as the precision of the plate overprinting. Products with high materials and thin materials are also printed in large format. Therefore, such blind printing process methods not only easily affect the production efficiency and quality of die cutting, cutting or punching, but also cause The increase in the consumption of base paper may even cause some of the products of the layout to be scrapped because the quality does not meet the standard requirements. Therefore, the author believes that large-format printing machines are suitable for printing production batches, and should have the characteristics of large finished products, no precise overprinting on the layout, and products printed with thick paper or cardboard to maximize the equipment. Performance, reducing the cost of printing production.
In summary, the transformation of packaging and printing products into a green production process is the general trend. We must have a forward-looking awareness, look at the impact and pressure of social development and progress on the enterprise from a strategic perspective, constantly change our ideological concepts and management concepts, and focus on continuous innovation from the aspects of production methods, production processes and production management. In order to improve production efficiency and product quality, and to achieve lower production costs, this is the most urgent goal of every printing company.