Where does the root cause of the perfect offset quality problem come from?
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In recent years, with the acceleration of the publishing rhythm, the number of books using flat-packed wireless glue-bonding is increasing. According to incomplete statistics, the books printed in China in the past two years are roughly in the billions of books, including more than 40. The 100 million copies are processed into a book using wireless adhesive binding. The thermal bonding material EVA hot melt adhesive used in bonding books and magazines is used nearly 10,000 tons per year; there are more than 100,000 units for bookbinding using such adhesive materials; the wireless adhesive binding equipment is only linked to the production line. Hundreds, there are more than 2,000 units. The processing of booklets by the glue-bonding process, the large amount of dry-cut materials used, involves a wide range of processing units, which has never been seen in the history of bookbinding. However, it can not be seen from the quality inspection of books in recent years that the quality of book binding is also serious. According to relevant parts, the non-conformity of binding is about 65% of the total quality of printed products, including wireless adhesive. The non-conforming products caused by the order processing accounted for more than 80%, and the unqualified products mainly reflected from the surface, after the processing of the book, the page fell, the back of the book was uneven, the book core broke, the bubbles, the holes, the glue, etc., the fundamental Where does the reason come from? Now we analyze from the following points, so that the relevant units can find out the reasons, solve the problems in the actual management work, and improve the quality of the perfect binding processing.
Insufficient understanding of the importance of changes in the post-press binding process
The post-press binding process is the final decoration process of the whole process of printing, and it is also the final finishing process of book processing. It is related to the preservation value and reading value of the printing products, and affects the above two processes (pre-press, printing). The processing effect and the guarantee of the cycle; no matter how good the printed products are, there is no correct and firm connection, beautiful outer packaging. It also does not reflect the value of printed products. Post-press binding is a very important process in the final packaging of the print.
For a long time, people have always had a prejudice against this process. They believe that anyone can do the job, but ignore the importance of it. At the same time, it also causes the cultural quality of the people who have been engaged in this work for many years to be lower than the prepress and printing process. As for the largest printing professional school in Asia, such as Beijing Printing Institute, it has not been bound for a number of specialized disciplines in the printing industry for many years. Only in recent years, there are some post-binding courses (within the packaging and decoration department). . In the large-scale printing information meeting, the printing scientific research meeting generally pre-presses and prints. For example, only the pre-press and printing and printing products complete the mission, and the books can be read without being booked. This situation will continue, will the quality of book binding not increase? The high quality of book decoration will affect the overall image of book publishing in China, so it must be really noticed.
Post-press binding is a processing process with complicated equipment, complicated process, many kinds of materials and great changes. There are dozens of equipments, more than 100 models and forms, and nearly 10 types of linkage production lines. Each line has a different model and form, and there is almost no commonality between the stand-alone equipment between the types of work. Post-press binding has evolved from a manual process to a modern process of mechanization, linkage, and automation equipment.
The post-press binding process is more complicated and has a large change. There are more than 10 types of loading methods. Some of the loading methods only have more than 30 processes, and the process changes when processing. How do publishers require processing to bind? The ability to meet the requirements is rarely valued.
There are hundreds of styles of materials to be bound, and each material involves a lot of knowledge. For example, there are more than 10 cover materials, and the textures are different. These different materials are in turn related to the use of bonding materials. The difference in the dry knots is related to the firming effect of the dead objects and the dead knots. Whether the material is used correctly or not directly affects the firmness and shelf life of the book. At present, the quality problems arising from wireless adhesive binding are directly related to the use of EVA hot melt adhesives.
In short, the post-press binding process is not only a complicated processing process but also an art processing process. Today's books are not only reading products, but also gifts, artworks, and valuable preserves. It not only adds knowledge to humans, but also Bring people artistic enjoyment. Therefore, the effect and value of the printed products must be expressed in terms of the quality of the printed binding. For our staff engaged in book publishing, production and other aspects, we must clearly understand the complexity of the process, the importance and the overall concept of making a book, and re-understand and understand the process for publishing high-quality books. .
The equipment has changed and the quality of the personnel has not changed.
Modern post-press binding equipment has entered a period of mechanization, automation and linkage production, especially after the mid-1990s, China has entered the third period of change of binding equipment, which is characterized by everything moving closer to international standards. At present, there are about 100 large-scale production lines in China, and the most advanced linkage line has a price of nearly 20 million yuan. Computer control, image display, etc., the equipment is getting higher and higher. These equipment management and operation require a certain level of technology. Management and operations personnel are competent. However, it is understood that there are very few talents in this area in China, and the existing skilled workers are far from meeting the expected requirements; generally, the equipment is coming. Some units only let the personnel train for a few days to operate on the machine. Most of the equipment is used to touch the dry machine and can be turned up. Therefore, the life of the equipment is shortened, the efficiency cannot be improved, the quality of the finished product can not meet the standard requirements, and the problem is not clear, the equipment is complaining, and the equipment is not found. The reason for people; in terms of the quality of the team in the post-press binding process, most of them are not graduated from professional schools, or even have not conducted any training. How can this be adapted to today's modern production? The equipment has become more advanced, and the quality of people has not changed. How can we keep up with the trend of the times?
The process materials have changed and the environmental conditions have not changed.
As far as the wireless adhesive binding process is concerned, almost every book processing factory has to be involved. Most of the cementing materials used in this process are thermoplastic EVA hot melt adhesives, and the thermoplastic bonding materials are very strict in environmental and condition requirements. At the Sino-German Binding Technology Training Course organized by Nanjing Aide Printing Co., Ltd., the German teacher Mr. Starr put forward the importance of environment and conditions when explaining the use of EVA hot melt adhesive, and introduced the EVA hot melt adhesive in France. The temperature and humidity of the workshop room for processing books have certain data control. The temperature is controlled between 19 °C and 25 °C, and the humidity is controlled at 50% RH. However, the temperature in the wireless binding production workshop is generally required to reach 17C-30C. Between; this requirement is twice as good as abroad. However, except for a small number of units and regions that can be achieved, most of them cannot be implemented according to this requirement. For example, the temperature in the south of China is high, and there are many units in the binding shop where there is no constant temperature or air-conditioning temperature. The temperature is as high as about 38 C, which causes the curing time to be prolonged after the application of the glue, and it is not hardened and shaped, and the linkage production line cannot be cut. In the north, when the temperature in the north is low, the indoor temperature is the lowest (no constant temperature, air conditioning equipment) to around lOC, which causes the hot melt adhesive to be cured before it can be bonded. As for the temperature, the difference is caused by the dry area. The standardization of the enterprise is not perfect (the general binding shop has no humidity meter device), and it is even more demanding to achieve the expected humidity standard; for example, the area with much rain in the south of China is humid and humid, and the humidity in the workshop is about 80% RH, while the north The area is less dry and the humidity is as low as 30% RH. Too low and too high humidity have a direct impact on the bonding between paper and books, which will cause various quality problems in the wireless glued book box.
In order to improve the quality of book binding. In the binding workshop, especially for hot melt adhesive materials such as EVA, it is necessary to create a good environment and conditions for standardized production.
Insufficient understanding of modern bonding materials
There are two kinds of bonding materials used for binding, one is cold hydrosol; the other is thermoplastic glue, which is divided into osmotic, attractive and semi-bonded forms after being melted and bonded with adhesive materials. Permeable (also known as semi-attractive), the three types of bonding materials used and the type of the object to be bonded are different, and the bonding effect is also different.
China's binding bonding materials have long used more cold glue, cold glue is a water solvent, and its drying method is determined by temperature and time after heating and pressing. The thermoplastic glue commonly used in modern times is different, such as EVA hot melt adhesive, which is a solid moisture-free fusible material. The material is used to pass the appropriate melting point (softening) temperature and the use temperature. , open time, curing time and cooling hardening time, and then correctly clamped and shaped, can achieve the reliable effect of dry knot. Because EVA hot melt adhesive is affected a lot when used, such as the temperature and humidity of the plant, the speed of the running speed, the difference of the paper texture, the different adhesives and side rubber, the temperature of the glue, etc. There are direct relationships between good and bad.
In addition, there are many publishers that require the thickness of the backing gum of the processing factory to be as large as possible. It is considered that the more smeared the stronger the smear, it is a misunderstanding. In fact, the fastness of the book joint is in a certain sense. Firmness is irrelevant. Because the strength, viscosity, viscosity, etc. of the adhesive can determine the fastness of the book bond. As long as the strength, viscosity, and viscosity of the book backing meet the standard requirements, the adhesive layer should be “thin and uniform”: the thickening of the book backing can only cause the back of the book to be uneven, difficult to read, ugly appearance and waste of rubber.
There are many types of cold and hot glue used for binding. Among them, EVA hot melt adhesives have different bonding effects due to different sources of basic materials, types of auxiliary materials and price differences of various ingredients. Therefore, we must fully understand the various materials used in modern use (including cover materials, cardboard, etc.), strengthen learning, understand it theoretically and then apply it to practice, record and use the experience at any time, and summarize the theory. Improve and achieve the desired requirements.
Publisher designers communicate less with the binding processing plant
In the past few decades, the publishing industry has been designing (especially the US) staff often with the technical staff of the binding processing plant. The teacher pays to contact each other to absorb the opinions of the binding workers to improve and improve the design plan to achieve the consistency between the design expectation and the product completion (ie, the imagination and the destination). Many high-quality products that have won international and domestic awards have been made. There are many well-known American artists who take the initiative to make friends with the bookbinding factory and masters, learn the binding process from them, and learn about various loading techniques to better design more excellent works. However, in recent years, this kind of communication is too little. At present, some younger American editors generally only pay attention to the information on the computer, but they are not diligent in going to the factory to learn from the masters and learn the knowledge that is not available on the computer, forgetting the practice. The truth of truth. Some people think that they are engaged in design, and they are the artists of the future. They can't put aside the knowledge of workers in the factory, so they have suffered a lot and learned a lot less. Therefore, there are many problems in the design and selection of materials on the size specifications. Here are a few phenomena:
1. Regardless of the value and effect of the bibliography, blindly pursue the wireless adhesive binding processing
The use (reading) value of the book, the preservation value is directly related to the correct selection of the binding process and the type of binding material. Generally, if you have a high-end book with preservation value, you should choose a long-term preservation of the exquisite packaging method; the binding material must also match the book grade to achieve the desired effect, the general book can be processed by universal packaging; simple and short use time For the book, you can choose the simplest method. However, it can be seen from the book market and the national book publishing situation that the number of wireless glue orders. It currently accounts for more than 60% of the total number of books installed. The author does not deny that there are many advantages to wireless adhesive binding, such as fast book release, short cycle, suitable for modern rhythm, and low labor cost, etc.; but this processing method also has many shortcomings, such as 1 resin glue Aging, not easy to save for a long time; 2 thick books are not easy to read and change: 3 is not strong bond, easy to drop pages, breaks, etc., has become the most problematic book binding quality problems.
However, some publishers are eager to publish books and want to reduce costs, but the books that should be soft-set or hard-processed with hardcover are hard to make a thick book of flat-packed wireless adhesive. As a result, the two sides were entangled. Hebei has a publication to do a 32-inch (A5) size, 4Bmm thickness of the book, indirectly asked the author can process the wireless offset paperback? The author replied at the time: "No! Either do hardcover, or do 2-3 copies of the perfect binding paperback...." It is conceivable that such a small book is really made into a wireless ordering, the result is ; A, can not read (not hold can not see); B, the front incision is not uniform, and the big belly becomes a rounded circle; C, the book looks modified; D, dropped pages, the broken book core break; E, The knot can not be firm, shorten the life of the book, and can not be preserved for a long time.
China is the world's first binding technology, but also the binding method, the most style. The oldest country has more than 10 kinds of installation methods, and there are 4 or 5 kinds of commonly used installation methods. The selection range is wide, but it is not normal to see what books are used in the current situation. Of course, the application should be used, and should not be used if it should not be used, and finally cause trouble, so that valuable books that are good at end can not be properly stored and used.
2. There are countless problems caused by cover selection and design.
There are a lot of books on the cover material that do not take into account the processing difficulties and effects, resulting in various quality problems. Here are a list of one or two examples for everyone to analyze.
1 The cover quality and the thickness of the book core are very different. In order to improve the effect of book decoration, there are many books whose cover thickness is different from the book paper thickness (or weight), which causes the tension between the two to be different. When the wireless binding is set, the cover is lifted to expose the book core. The bottom of the rubber or the sample page causes the non-conforming product, and the publisher and the processor have contradictions. If this type of product adds a gram of (thickness) moderate lining or lining between the cover and the first page of the book block to solve the problem of leaking the bottom, many publishers do not intend to reduce the cost. Does not consider the processing effect.
2 The cover paper is not properly creased. Now the thickness of the cover is getting bigger and bigger. The paper jam or paper with more than 200 grams has a folding front process. When the indentation breaks, the broken seam breaks the bottom and destroys the appearance quality of the book box. In fact, the cover of 200g or more has to fold the front mouth, which makes the binding of the book very difficult, and can not guarantee the quality, so it also causes quality problems.
3 The length of the cover is shorter than the length of the book block to cause a dirty book. When the book is booked, most of the cover length is about 7mm shorter than the length of the book block. As a result, when the glue is glued, the back of the book is short, which causes the exposed part of the book to leak the dirty book. If you leave the head in the cover design, the size of the edge of the foot, this phenomenon can be completely avoided.
4 design patterns leave no room for processing. There are also some American styles that do not count the pattern, the cover of the frame does not take into account the difficulties in binding processing, do not understand the quality standards of the binding, deliberately pursue the appearance of beauty, the results can not achieve the desired effect when binding. For example, if a processing unit receives a paperback book from a publishing house, the thickness is 12mm. The back of the book, which is designed to be sealed, is divided into all white and printed with black characters. The full version of Feng Yi and Feng Si is black and white, requiring the processing factory to not cover the back of the book when processing. This kind of request is too difficult. According to the national CY/128-1999 binding quality requirements and inspection methods, the provisions of Articles 3, 4, and 5: the translation error of the book back is based on the center line of the book back, and the finished book with a book back thickness of 10 mm or less. ≤1Omm; the book back thickness is greater than 20mm, and less than or equal to 30mm finished book, the book back word translation tolerance is 2.5mm; the book back word thickness is more than 30mm in the finished book, the book back word translation tolerance is 3.Omm. The book back word is skewed The tolerance is 0.5mm smaller than the tolerance of the back of the book. So, this black and white design, how can the ideal effect be achieved by the harsh requirements of the processor? There are too many examples. I hope the publisher wants to bind with the book. The processing unit knows more about the common communication, correctly understands the overall concept of a book, and works together to make a good book.
Cultivation of talents that are not focused
After the market economy, the competition in all walks of life is very fierce, and there is a great potential for you to live and die. The key to competition is nothing more than eight words, namely, "talent, quality, equipment, reputation". The first is talent, with technology and business talents. Still afraid of not getting a good product? However, as far as the analysis of the professional situation is concerned, due to the poor cultural quality and the lack of a college to train this professional and technical talent, it is very difficult to find a professional teacher. According to the complexity and variability of this profession, it is impossible to adapt to the modern development without putting the talents in this aspect on the agenda.
It is understood that there are more than 100,000 training and binding workshops in the country, and the number of people engaged in binding work accounts for I/3 of the total number of jobs (prepress, print, and postpress) in the printing industry. Such a large professional team, There is a serious problem of talent training that is very inappropriate. Here are a few examples for everyone to understand.
1. Personnel are not trained. It is understood that there are more than 100,000 wage-earners (sisters) in the country, and there are only a few thousand in the suburbs of Beijing. They work as soon as they enter the factory. They do not learn or train. They learn while doing it. Not even the master.
2. Some enterprises will cultivate talents and improve product quality. They are willing to spend money to invite customers to forgive, and do not want to spend money to train workers to learn technology.
3. Some business leaders and bosses dare not train workers to learn technology, and understand that "when they are trained, they will change jobs."
4. Some leaders do not want to let the workers go out to study during their term of office, for fear of re-election to the next leader to "cook and eat" and so on.
With such an idea, how can we talk about improving the quality of workers and cultivating talents to improve product quality?
In short, the various quality problems that occur in post-press binding, especially the falling pages reflected in the recent wireless adhesive order, the unevenness of the book, the wrong post, the broken book block, etc., are all representations, the root cause is In many ways, we must fundamentally understand, treat, research, and propose solutions so that we can catch up with the rhythm of society and truly achieve results in improving product quality.