Printing fluid full process solution under the concept of Industry 4.0
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What we want to share with you today is the whole process solution of printing fluid. This is a whole process solution according to the overall flow sequence of water and gas in offset printing. From the front-end source to the final end, we give this solution internally. The solution has a serial number, so its name is also called "one two three four five."
1. Centralized printing water pretreatment system. Water with a high hardness cannot be directly used for printing. Otherwise, the consumption of dampening solution will be aggravated, the rubber roller will be crystallized, the service life of the rubber roller will be shortened, and the printing quality will be lowered. Therefore, tap water cannot be used directly for printing, but requires pre-treatment of concentrated printing water. Rex's centralized printing water pretreatment system, a printing plant only needs this system, can convert all the printing water of the printing machine into water that meets the printing standard. There is no clear standard for printing water in China. The German standard BH8, which is the hardness grade, represents the number of grams of calcium oxide per liter of water. BH8 means that 80 grams of calcium oxide per liter of water. This water is the water that best meets the printing standards. Turning tap water into standard printing water is what the system has to do. This is the first step in high-quality offset printing, but unfortunately, many companies are wrong in the first step.
2. Concentrate dampening solution to manage cooling and water supply systems. We have a calculation that water is at least 50% important in traditional ink offset printing. As we all know, most printing plants carry out dampening solution management, which is equipped with a water tank system for each machine. This will result in different dampening fluid status for each press in the shop, and the overall print quality is entirely determined by the captain's personal preferences, rather than unified management.
Unlike this, Rex's centralized dampening fluid management cooling and water supply system is a completely conceptual change that unifies the management of all press fountains in the offset shop, ensuring print quality integrity. At the same time, the system also fits the needs of the printing company's machine substitution. According to statistics, the time required for the captain or operator of the offset press to operate water-related equipment is about 35 minutes, which is about 10% of the working time. After centralized management, the centralized system will directly transfer the standard-compliant dampening solution to the sink of the printing press without any human intervention. This will provide a very good equipment foundation for future reduction and reduction of workflow. . We have many practical cases. For example, in France, a customer has a complete centralized system, and all the equipment can be armed to open two printing machines by one person. At present, the cost of labor for printing companies in China is very high. In the future, it is possible to reduce the use of printing workers in large quantities. This is a very serious problem for large printing plants. This system can provide a better solution.
3. Concentrated dampening solution precision filtration and emission reduction system. After the printing process, everyone will find that the water is dirty, and the direct result of dirty water printing is the sharp decline in printing quality. Correspondingly, the direct benefit of our system is to improve the quality of printing. There is also a quantitative standard for determining whether the dampening solution meets the requirements after the filtration process. Rex uses the German standard, one looks at the number of particles in the fountain solution, and the second looks at the change in chromaticity. Originally in Europe, filtration is a tool to improve print quality, but in China, it has another layer of meaning that can help printing companies to reduce emissions. The system reduces the discharge of dampening fluid by at least 10 times per year.
Summarize the first three steps, one is to convert the tap water into printing water; the other is to convert the printing water into a qualified dampening solution, and spray it to each printing machine in a centralized manner to achieve uniform quality printing; The plate solution can be reused as long as possible.
4. Centralized printing waste liquid sewage treatment straight discharge system. We divide the waste water from the entire printing process into three parts – prepress, printing and postpress, because the three components need to be treated differently and the price is different.
The main waste liquid before printing is the plate water and developer. We will discharge the waste into the system. Through high-temperature distillation, the final plate water can continue to be reused, and the developer will concentrate the concentrated waste liquid that needs to be discharged. The data shows that every ton of recycled water can be flushed to 2000 sets, and every 100 tons of developer waste is finally concentrated to 5 tons of concentrated waste, which greatly reduces the cost of sewage charges.
The waste liquid produced by printing, the most important is dampening solution and car wash water. For printing waste, our standard is to reuse as much as possible. This system will collect all the printed waste liquid into a large container for stratification, which will inevitably lead to a phenomenon - oil is on, water is under, suspended matter is in the middle, and then processed separately for these three layers. The oil will enter a treatment system, and finally produce regenerative car wash water that can be reused. After the water is extracted from the bottom layer, the final output is the medium water that meets the national secondary emission standard, and can be connected to the medium water irrigation system or the reclaimed water of the printing enterprise. The rinsing system is recycled; the intermediate solid waste liquid is subjected to high-pressure concentration treatment, and finally solid waste is formed, which can be directly thrown away or burned (in Europe, there is a special enterprise to recycle such waste, which can be sold to some companies, which is very Good fuel for help). The oily substance becomes a reclaimed oil and can be used in time. Moreover, the reclaimed oil and the new oil can be mixed in a 1:1 ratio, which not only causes the waste oil to be discharged, but also saves half of the cost of purchasing the car wash water every year.
5. VOCs printing exhaust gas treatment system. Unlike all previous solutions, Rex uses ZedTM zeolite rotation technology for professional VOCs processing. The core component of the technology is called the zeolite wheel turntable. ZedTM zeolite is a synthetic crystal. The structure of this crystal has a very good characteristic. Its molecular structure will completely lock the VOCs, and then the VOCs will be released by changing the temperature of the environment and unlocking the molecular chains. We use this feature to design this system, which has a part of the adsorption zone and a large amount of adsorbed VOCs. After the wheel turntable turns to a specific angle, we heat and press the wheel turntable to let it release all the VOCs. The advantage of this system is that it only absorbs VOCs, and finally releases it to a certain extent and then releases it. After the release, we collect it. The burning is pure VOCs, and the energy consumption is very low. The advantages of zeolite technology, first, is the best centralized VOCs treatment technology so far; second, the concentration treatment can reduce energy consumption; third, completely maintenance-free, no maintenance is required, and there is no need to replace consumables later; Fourth, it can be used for 15 to 20 years. Fifth, no matter how the national policy is improved in the future, this method can meet the requirements of national policies because it is designed according to German standards.
Finally, I want to end today’s speech in one sentence. That is, from our professional point of view, printing is really not a polluting industry.