The experience of the water offset printing system technical transformation project
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As an old employee who has worked in the offset printing machine for more than 20 years, the author always feels: "If you want to produce a first-class product, you must know the equipment you are operating. You must be familiar with the advantages and disadvantages of the equipment and have to deal with it. The ability to make basic mechanical failures."
Of course, this is not a one-off effort, and it requires constant research and hard work. In order to continuously improve the operation technology and capabilities of its equipment, the author has always insisted on operating the Heidelberg CD102 6+1 offset press purchased by the company in 2009. Because the device is now aging and often needs to deal with various faults, the author has accumulated a lot of experience in the operation process.
In September 2016, in order to further improve the production capacity of offset printing, our company introduced the “zero alcohol lithography system” (also known as “tap water offset printing system”). I have the privilege to participate in the whole process of the system from field trips, installation tests to professional training, where I share some experiences with my peers.
Visit
During the visit, I was most impressed by the fact that when I visited the offset printing production site of Yunnan Qiaotong Packaging and Printing Co., Ltd., I first felt that there was no pungent smell of isopropyl alcohol in the entire offset printing workshop; Chatting very easily, there is no such thing as a busy and tense machine.
The author thinks: "God! These employees are too bold. Even if they have the best technology, if they don't keep an eye on the machine, it is easy to produce waste. Are they not afraid?"
After the author's own equipment is also installed with the tap offset printing system, it is clear that the offset printing operation can be very simple, and the advantages of the tap offset printing system can completely compensate for the defects of the old equipment with 20 years old, and the products produced. It can be compared with the products produced by another new equipment of our company.
Technical transformation and testing
Yunnan Zhuoyin Technology Co., Ltd. (hereinafter referred to as “Zhuyin Technology”) completed the installation and commissioning of our company's tap water offset printing system in just one day, and then carried out a morning technical training for the machine personnel, which made the staff very I quickly mastered the operation skills and precautions of the tap offset printing system, and soon officially put into production.
Our company has tested the tap water offset printing system. The test version has 6 colors, namely black, cyan, magenta, yellow, special 1, and 2, and the test results are shown in the following figure. It can be seen that after using the tap water offset printing system, the ink is hardly destroyed, the color saturation in the field is better, the edge of the dot is relatively real, the dot gain is extremely low, and the color reproduction is very good.
Intuitive feeling
After the tap offset printing system was put into use, the author truly felt the charm of technological innovation. Previously, it was necessary to add isopropyl alcohol to the water tank, which not only gave off a pungent smell, but also the color of the water was dark, and the water was shut down every week. The harsh working environment makes people feel very uncomfortable.
Now the machine where the author is located is no longer using isopropyl alcohol. The water in the water tank becomes more and more clean. It does not need to be re-exchanged and can be recycled all the time, thus greatly reducing the emission of VOCs and improving the air quality of the workshop. It not only saves costs, but also benefits employees' health and eliminates fire hazards.
In addition, the most important thing in the offset printing process is the ink balance, which directly determines the stability of the hue, and the most difficult thing for the operator to grasp is the ink balance.
This is because the surfactants in the fountain solution, such as alcohols and ethers, are the same as the volatile organic compounds in the ink. According to the principle of similar compatibility, the surface structure of the ink is quickly destroyed, so The stability is also destroyed, resulting in an uncontrollable emulsification rate of the ink.
Every time it is turned off and then turned on, it will be obviously different. If it is stopped for 3 minutes and then turned on and stopped for half an hour, it will be different, which directly leads to unstable hue. Therefore, it takes a lot of time to adjust the color after each shutdown and power-on, and it can be restored to the state before the shutdown by using dozens or even hundreds of sheets of paper.
After using the tap water offset printing system, there is no component in the dampening solution that can dilute or dissolve the ink. Therefore, at the intersection of the printing ink layer and the dampening solution layer, the ink is not eroded by the dampening solution, and the oil and water are not realized. Solubility solves the problem of ink balance.
This makes the color of the printed product very stable, the ink is dried faster, the dot is restored, and the color saturation is high. Especially for the printing of high quality requirements, anti-counterfeit barcode, large solid, white ink, gold and silver ink, etc., the performance is even better. Improve the stability of printing quality, improve production efficiency, and make the offset printing operation more convenient.
In short, the tap offset printing system completely solves the problems brought by traditional offset printing, and is a revolutionary product in the true sense of environmental protection and subversion of traditional offset printing.
First sight
Our company mainly faces the tobacco companies in various provinces and cities, and undertakes the cigarette package printing business. In recent years, the process requirements for cigarette package printing have become stricter, and relevant standards have been introduced to detect VOCs. The complaint rate and environmental protection issues have increased. The introduction and use of the water offset printing system has made our company's printed products fully meet the standards in all indicators, and won praise from customers.
Now I don't have to worry about the hue instability caused by various shutdowns and restarts. I don't need to let go of the paper for 3 minutes. If I stop the paper for about half an hour for more than half an hour, I can recover the hue before the stop. Great.