How Can Tianwen Printing Achieve A New Leap By Investing 1 Billion Yuan To Build A Fully Connected Intelligent Factory?

In the era of deep integration of technological change and industrial revolution, new quality productivity is rapidly reconstructing the underlying logic of traditional manufacturing industry. As a benchmark enterprise in the field of book and magazine printing, Hunan Tianwen Xinhua Printing Co., Ltd. (hereinafter referred to as Tianwen Printing) has built a new production system that is intelligent, green, and collaborative through systematic technological innovation practice. It provides an innovative model for solving common problems in the industry such as "unstable quality, high loss, and low efficiency", and also explores a new path for the ecological reconstruction of traditional book and magazine printing industry.

Building the foundation of digital intelligence: constructing a full chain intelligent factory
Faced with the new development trend and competitive landscape of the industry, digital transformation has become the key for enterprises to enhance their core competitiveness. Tianwen Printing focuses on the two core goals of "improving quality" and "increasing efficiency", actively exploring the application of digital technologies such as artificial intelligence, cloud computing, big data, and the Internet of Things in the book and magazine printing industry. With technological innovation as the engine, it deeply explores effective mechanisms for the integration of culture and technology, achieves beneficial interaction and two-way empowerment, and promotes the evolution and upgrading of product quality management systems towards digitization and intelligence. By improving product acceptance standards, stabilizing the quality characteristics of raw and auxiliary materials, enhancing the manufacturing accuracy of automation equipment, and promoting the digitization of equipment technology standards, we aim to push product quality to new heights.
Tianwen Printing has launched a comprehensive digitalization construction project with a total investment of 1 billion yuan. The project is guided by the principles of "quality standardization, intelligent production, scale production capacity, and comprehensive services". By building a new generation of information system covering "intelligent operation, intelligent production and manufacturing, intelligent warehousing and logistics, intelligent marketing, and intelligent supply chain", supporting intelligent production equipment, strengthening the integration and application of advanced manufacturing technologies in the Internet of Things and printing, achieving production data connectivity, manufacturing flexibility, and management intelligence, constructing a modern book and magazine printing and manufacturing service system, and comprehensively improving enterprise efficiency, quality, and customer satisfaction.

Breakthrough in Science and Technology Innovation: Breaking through the "bottleneck" technological barriers
Tianwen Printing adopts a dual wheel drive strategy of independent innovation and collaborative research and development, accelerating the cultivation of high-tech, high-efficiency, and high-quality productivity. In the past three years, a total of 150 million yuan of research and development funds have been invested, and fruitful achievements have been made in the fields of scientific and technological innovation such as new technologies, new processes, new materials, and management system informatization. A total of 36 independent intellectual property rights have been obtained.
In the pre press stage, Tianwen Printing has established a deep cooperation with software service providers to address pre press processing issues caused by human errors during file comparison. Guided by customer needs, they have jointly developed a file comparison application software. By comparing and verifying the printed and typeset files, ensure the consistency between the final output file and the original manuscript. This system has strong recognition ability for subtle deviations in the production process of products such as multi version textbooks and shared file teaching aids. It can accurately identify some hidden quality issues that are easily overlooked in manual verification. Through automated comparison and verification, various production errors have been greatly reduced.
In the printing process, Tianwen Printing utilizes machine vision to analyze product defects through automatic registration systems, automatic cutting systems, online quality inspection systems, and automatic rejection systems, achieving quality management that is preventable and controllable. For example, the developed online quality inspection and automatic rejection system can achieve online quality inspection of the first printed sample at a detection speed of 55000 copies per hour, and automatically proofread it with pre press documents. It also provides reference samples for continuous production and can complete inspection, mark defects, or cooperate with the automatic rejection system to achieve online automatic rejection function without stopping the machine at high speed; The automatic nesting system, with its precise positioning detection and mechanical control device, has successfully overcome the problem of folding accuracy, such as the easy occurrence of folding position deviation during high-speed operation of rotary printing machines.

In addition, the application of automated devices such as automatic feeding of paper rolls, automatic bundling of book stickers, and automatic palletizing has achieved efficient linkage between various processes. Among them, the automatic paper roll feeding system breaks down the automation barrier from the transfer of roll paper to the production process, realizing unmanned operation throughout the entire process from paper retrieval from the warehouse to card loading on the production line. It not only reduces the labor intensity of workers, but also ensures the efficient and stable operation of rotary printing operations; The rotating book collection and bundling code plate system adopts a unique vertical clamping structure, combined with paperless friction and secondary adjustable slow pressure design, effectively avoiding the problems of rubbing and pressing of printed products during bundling and stacking. Through automatic plate addition and automatic stacking, it further releases manpower and provides a reliable solution for automatic pasting in the binding process.
In the post press stage, Tianwen Printing introduces intelligent devices such as automatic book feeding, automatic stacking, bundling, palletizing, labeling, and automatic packaging, which work together with binding equipment such as graphic and text error detection system, micro character coding system, online high-speed dynamic weighing system, cover automatic alignment device, and automated post-processing equipment to achieve dual improvement in quality and efficiency.
The vertical bundling and automatic stacking system developed by Tianwen Printing innovatively adopts a vertical stacking method, greatly saving production space and closely cooperating with the rotating book bundling code plate system, successfully connecting the entire automated operation chain from printing to binding and page matching. The automatic pasting robot has replaced the most labor-intensive process in post press binding production, reducing manual intervention and avoiding the occurrence of errors and mistakes.

Vertical bundling and automatic stacking system for book stickers

Online image and text error detection system
In addition, the online high-speed dynamic weighing system is embedded in the finished product conveyor line of the adhesive linkage line, which can accurately identify and eliminate finished books with errors exceeding 1 gram and cutting skewness online, further ensuring product quality. The new "mirror version" plate material jointly developed by Tianwen Printing and its industrial chain partners has completely overturned the traditional electrolytic oxidation plate process, achieving emission reduction from the source. It mainly presents the following characteristics:
Firstly, it has excellent wetting performance, with a wetting angle of less than 5 °, making ink balance faster and more stable. Only half of the water film of traditional plate materials is needed to block ink erosion;
Secondly, the reproduction ability of the dot matrix is enhanced by combining the microporous structure of the aluminum plate with the superhydrophilic layer, which enhances the sharpness and fullness of the dot edges, significantly improving the precision and replication level of printed materials;
Thirdly, the resource consumption is low, with a 30% reduction in the amount of lubricant used and a 15% reduction in the total amount of ink. The ink drying speed is greatly improved, and the scrap rate of the rotary machine can be reduced by 30% to 60% (the old models have a better reduction);
The fourth is to improve the quality of printed materials. The thinning of the water film effectively inhibits ink emulsification, reduces the moisture content of paper ink, and reduces the loss of dirt and rubbing, which can improve the color rendering and chromaticity of ink. At the same time, it effectively improves the problem of printing "ghosting" faults, and the quality stability is improved

Collaborative Innovation: Reshaping the Ecological Coexistence of Industries
The cultivation of new quality productivity cannot be separated from the ecological environment of collaborative innovation in the industrial chain. Tianwen Printing actively collaborates with upstream and downstream enterprises such as equipment manufacturers, material suppliers, software service providers, etc., forming an innovation consortium to carry out deep cooperation in the fields of intelligent equipment research and development, process technology innovation, and cutting-edge technology applications, providing replicable technical solutions for the industry. This technology spillover effect is driving the evolution of the book and magazine printing industry from a "single point breakthrough" to a higher stage of "systematic innovation".
Standing at the critical point of industry transformation, Tianwen Printing calls on partners from all walks of life in the industry to jointly engage in future technological research and exploration of book and magazine printing. Only when the flame of innovation ignites a prairie fire can the traditional book and magazine printing industry truly achieve an ecological transition from "manufacturing" to "intelligent manufacturing" and radiate vitality in the new development pattern.

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