Equipments

Rapid die change for automatic flat die cutter

The time of die change for conventional automatic flat die cutter is about 40 minutes, if you take the right methods, it can be controlled in about 6 minutes. It can be seen that the automatic die - cutter for rapid die change can greatly improve the production efficiency. This paper introduces the following practical methods for automatic flat die – cutter die change.Rapid die change standConventional automatic flat die-cutter does not have a rapid die change stand, two template frame must be adopted if use of rapid die change stand, the specific methods are as follows:Templates are divided into A template and B templateAfter the production of A template is completed, pull out the A template,it into the quick die change stand, and then put the B template into the equipment to install the template. After the installation, start debugging the production parameters of B template. After the normal production, the removal of A template will begin. Then C template will be installed, the templates are used alternately in this circle way.By doing this, it is beneficial to change the die tools, which directly reduces the time of installation and disassembly, which is conducted during the production, greatly reducing the time of die change.Of course, if you want to change the die more quickly, you have to solve the pressure problem. Most of the time are being wasted in adjusting the pressure. The following two tools will help you solve the pressure problem:Use multiple template base plateDie - cutting base plate can be stocked more than one, if the company's products are relatively few, it can consider to prepare at least one base plate for each and every product. Using the same die cutting plate is to ensure that the pressure from beginning to end has been kept low, die force surface is consistent.Use pressure die Put the pressure die underneath the bottom die in the first debugging die cutting pressure, as long as the adjustment being done, the bottom template and pressure die formed a pressure system, so in the next production, die cutting pressure will not be adjusted as long as it is the same as the last time.Through the three aspects of the improvement, the production efficiency of the die cutter can be greatly improved: if each time for die change needs 40 minutes, five times a day, about 200 minutes in total. After the improvement, each time only 6 minutes, so as long as 30 minutes a day, in this way, every day can save 200-30=170minutes, that's 170*30= 5,100 minutes per month, which is equivalent to a unit of one week's work time, this is the value of rapid die change.

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Slotting unit operation and process adjustments

By explaining the principle and operation of the slotting process, this paper guides the operators to solve the slotting problems in a targeted way. The content involves the s and principles of the slotting equipment, the adjustment of the slotting equipment, and the inspection of the poor slotting problems etc.1. Principles of slotting unitScoring and slotting unit refers to scoring the cardboard with the height of the carton, and cutting the flap transversely. The slotting and scoring unit include slotting unit, scoring unit, cutting corner unit and trimming unit. The main is to make the A flute carton go through the above procedures.In the slotting process, especially for a piece of molded carton, there are two scoring lines that are very important. It needs to fold 180 degrees in the process of gluing and stitching, while other two only need to fold 90 degrees, and it is folded after carton formation. In this case, these two lines are going to be scored deeply.Slotting unitThe slotting unit is mainly used to cut a certain width and depth of the flap. The slotting unit includes the upper slotting knife, the lower slotting knife and the scrape knife. When the height of the box exceeds the maximum distance between two knives, the operation of removing the knife should be performed. It takes a long time to install the knife and the position must be adjusted accurately, otherwise it will cause damage to the equipment and tools, reduce the production efficiency and increase the production cost.The lower slot cutter is two circles composed of four semicircular steel plates, the distance between which is exactly the thickness of the upper slot cutter. The scrap knife is to remove the remaining paper scraps in the lower slot knife to avoid paper jam and stop the machine.In the process of slotting knife operation, it will encounter a lot of problems, slotting knife itself has a certain thickness, in the case of slotting gap is very narrow, that is, the width of the carton is very narrow, two knives will touch. In this way, the carton can not be cut, at this time we need a double-axis knife holder. The double-axis knife holder has two knife holders in the front and back, which do not affect the movement of the other knife. In this way, the slotting width with zero spacing can be achieved. Most slotting tool holders are uniaxial, as there are very few such narrow cartons.Slotting knife has a feature, that is , best to use tooth-shaped knife. Because the tooth form knife will not form a blade, which is easy to cut into the paper, and not easy to form burrs and cracks. Scoring unitThe main of the scoring unit is to press out several lines to facilitate the molding. The scoring unit is made up of two scoring wheels, the top is pointed and the bottom is curved. There is a special point to pay attention: that is the pre-creasing wheel. This has become a standard configuration of slotter. The cardboard is not easy to cause extrusion flute after pre-creasing.Corner cutting unit The corner cutting unit is mainly divided into knife base, blade and anvil. Its is to cut the excess paper at both ends of the tongue off. At present, the advanced slotting unit will be using a high-quality rubber gasket under the corner cutting, so that the mechanical vibration is all, and the cutting is very clean. Of course, some of the equipment itself is made of steel, it is recommended to make some all changes to the equipment, so the effect is better.Trimming unitThe trimming unit is two semi-circular steel trimming knives, the main is to cut off the redundant paper edges.For the carton with very high requirements for slotting, both sides of the cardboard need to be trimmed to make the size of the carton more accurate. It is recommended that not to trimming. Because when in the corrugator production, if the cross-cutting transformation is better, the size error of the cardboard length direction is very all, which can be controlled in 1-2mm. If it is not to positioning based on the carton tongue edge, such error is acceptable, so the trimming unit is less combined with slotter.Coupling typeThe drive of the transverse moving cutter has two modes: the coupling type and the chain type. The coupling type is better than the chain type, the tranission accuracy is higher, but the price will be a little more expensive as well. In view of the current high production precision requirements, it is recommended that we use the coupling type.2.Quality requirements for slotting unitIn the process of slotting, four quality problems are generally considered:●The carton capacity size is accurate;●Reduce damage, maintain the maximum strength of cardboard;●Formation is neat and beautiful;●The automatic packaging process is ooth, without the impact of carton cover.During the operation, we should pay attention to the following five problems:●Scoring line should be deep, the folding line of the carton should be more clear and beautiful with uniform seaming.●The effect of pre-creasing damage is obvious, the flute that is to be scored must be crushed, so that we don’t need an excessive extrusion in the process of folding, in this way , scoring cracks can be reduced.●The mark of scoring and slotting should be in alignment, which can avoid the carton flap and box shrinkage to affect the appearance of the carton.●Avoid lifting paper with slotting knife. If the knife is not adjusted properly, the slotting incision will be lifted up to form a crack, which will affect the appearance of the carton.●The carton should be compressed at the overlapping part, namely the tongue part. If not, when the carton is formed, the thickness of this place is the thickness of two pieces of cardboard, which is not convenient for stacking.3.Analysis on quality abnormality of slotting unitIf cardboard indentation is not obvious, resulting in poor formation and size deviation.Possible reasons:●The upper and lower scoring wheel gap is too large, resulting in insufficient pressure.●The scoring wheel rubber anvil wear, the circumference became aller.●Cardboard with high strength or fast running speed, resulting in scoring wheel shaft strength is insufficient. Because the cardboard has a certain hardness, the scoring wheel is just a stressed wheel, if the cardboard strength is too large, coupled with the speed is very fast, the wheel on the cardboard will stay on a short time, plus the cardboard rebound is large, so the scoring will be poor.●The shape of the scoring wheel does not meet the requirements. It is out of shape, so it cannot be scored in the place with the allest circumference, and it is too deep in the place with the largest circumference.Solution:●Adjust the upper and lower scoring wheel gap.●Replace the rubber anvil of the scoring wheel.●Reduce the running speed or overcome the insufficient strength of the scoring wheel shaft.●Replace the proper shape of the scoring wheel.The upper and lower width of the slotting part is different, and the width of the slotting knife is different when cutting the layer paper and the bottom paper, resulting in burrs and cracks. Possible reasons:●The slotting knife is passivated.●Use a flat slotting cutter, not easy to stick into the cardboard;●The slotting cutter cut the lower round knife too deep.Solution:●Replace the slotting cutter.●Replace the tooth shape slotting cutter.●Adjust the depth of the slotting cutter cutting into the lower round cutter.Paper lifted in slotting unit Possible reasons:The tip of back slotting cutter is too high, just at the moment when the cardboard feeding out after slotting, the knife is still in the cardboard, and the knife plate below has left, therefore the knife directly stabs into the cardboard.Solution:●Reduce the height of the slotting tool tip so that it leaves the cardboard surface synchronously;●It is necessary to grind the height of the slotting tool tip, because the passivation of the knife will also result in the knife and the cutter not leaving the surface of the paper at the same time.Slotting and scoring offset or skewPossible reasons:●Paper biting is not tight, the cardboard is moving;●The scoring wheel is offset from the slotting cutter, and the center of scoring is at the center of the slotting. If the two centers are not aligned, the slotting and the scoring are definitely not centered.●The toggle plate of the cutter seat or scoring wheel seat is worn and the gap is too large.Solution:●Adjust and check whether the paper biting is suitable.●Adjust the alignment position of the scoring wheel and the slotting cutter.●Change with the toggle plate or adjusting plate.The front and back slotting position dislocatingPossible reasons:●Cardboard transfer process shift;●The phase mechani produces errors.●The tool base is loose with the tool shaft.●Paper biting is not solid, cardboard shift back and forth.Solution: ●Overcome cardboard displacement;●Overcome the phase error of the machine.●Lock the adjusting part of the slotting movable knife;●Adjust and check whether the paper biting is tight.4.Inspection and maintenance of slotting unit equipment●Check the gap of the pre-creasing wheel Check the actual position and setting data of the ram with a feeler every week. Generally, we only look at the dial of the slot, but because of the pre-creasing wheel often friction cardboard, the dial will be showing the error, the actual data and the setting data is not necessarily the same, so it is recommended to use a feeler gauge for thickness inspection every week.●Check the gap of the scoring wheelJust like the pre-creasing wheel, check the actual position and setting data of the ram weekly with a feeler.●Check the size of the slotting cutterUse steel tape measure to collect actual measurement and display data. Because the knife plate is made of steel, there will be heat expansion and cold contraction, especially in summer and winter, there will be some slight differences.●Check the alignment of the upper and lower slotting cutterCheck weekly, rotate the upper slotting cutter, and visually check and locate before putting the lower slotting cutter to avoid the situation of knife collision.●Check the gap between tongue and bladeAdjust the angle tool holder every week, usually rotate the upper slotting cutter to the lower slotting cutter’s highest point, then adjust the angle tool holder. Because only the highest point being adjusted well, it is the correct entry position.●Check the chain tension of the moving knife holderWeekly check with hand pressure, pay attention to the length of the chain that can not exceed 3mm, if too long, left and right movement will be inaccurate.The whole process above can be divided into six steps:●Shake left and right with your hands. Check whether the pre-creasing wheel and scoring wheel are loose. If so, we should firstly deal with the gap between the guide plates.●The upper and lower slotting cutters should be checked for looseness after separated, If loose, we should firstly deal with the gap between the guide plates.●The upper and lower pre-creasing wheels and the scoring wheels are respectively painted with different colors, and the paper is fed into the slotting unit.●Loosen the adjusting chain or coupling shaft, and turn the lead screw to adjust the upper and lower pre-creasing wheels, and the upper and lower scoring wheels to the position aligned with the slotting center.●Test again by repeating from the first step, and adjust after measuring the deviation.●The adjustment of the slotting knife's up and down alignment, first remove the slotting knife, thenthe slotting knife into the lower slotting, turn the screw rod to adjust to the slotting knife, if the screw rod canthe slotting cutter, then we can install the chain or coupling shaft back, finally to adjust the tightness.Here are some details to be noted in the adjustment process:Crushing wheel: The gap should be less than half of the thickness of the cardboard on the basis of not crushing.Scoring wheel: The gap is about half of the crushing wheel on the basis of not crushing.Slotting cutter: The gap of upper knife cutting into lower knife is about 3mm, the gap of paper clamp is about 5mm, and the upper or lower seat is taped with sponge.Shaft and screw rod should be cleaned every day and wiped with low viscosity oil to ensure ooth movement. Do not use anti-rust agent for lubrication.

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How to avoid problems in debugging?

It has skills to debugging printing press, not just by feeling. If you pay attention to the following points, many common carton printing problems can be avoided.1.Make sure adjust the plate pressure to zero : Hanging the plate (preferably full-page), and slowly reduce the gap between the anilox rollers, 90% of the inking area is the zero of plate pressure.Note: The front end of the printing pattern is not neat if the plate pressure is too large. Also, this gap needs to be calibrated monthly.2.Zero adjustment of printing pressure: Take double wall of flute B as an example, slowly reduce the plate gap, ensure 90% of the full-page printing area is inking. At this point, the electronic control value minus the thickness of the cardboard is the zero of the printing pressure. During normal operation, the printing pressure is about 0.2-0.5 mm lower than the cardboard. The back side of the printing surface will be irregular if the pressure too much.Note: This gap needs to be calibrated monthly. 3.The principle of adjustment of printing feeding roller is the same as printing pressure.4.In principle, the thickness of cardboard should not be reduced by more than 5% during the production, otherwise the carton compression will be seriously affected.5.During the process of production, when the printing press was accelerating, if the cardboard is overall running dislocation, the pressure of the pull rolls should be increased, and the printing pressure should be increased from the back to the front, otherwise the printing blanks will be occurred.6.In the production process, the cardboard without downward warping often appears slotting run-off, the main reason is the transition from the last color of cardboard to slotter entrance is not good, so that the cardboard will hit the lower slotting knife. Problem can be solved by adding transition plate.

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Six methods to reduce cartons chromatic difference

1. Stable ink quality Stable ink quality is the key factor to control chromatic difference. Now many customers will compound spot color ink in order to promote the uniqueness of their products and increase security features. Spot color ink ratio must be accurate, so as to ensure a stable ink hue, and the brightness, saturation can meet the requirements.If ink quality changes, it will lead to a large discrepancy. The technical content of ink mixing is relatively high, so the requirements for experience are also very high. If enterprises without owning ink mixing specialist can request ink manufacturers sending technicians to offer door-to-door service. In short, the quality of ink affects the overall effect, it must be carefully selected and used.In the process of using ink, there exists a series of problems including viscosity increase, ink distribution, hue change etc. after volatilizing. These need to be timely adjusted according to specific situation. In the printing operation, front-line staff, especially the captain, will find out many effective methods and all innovations in practice. All proven effective methods should be actively summarized and promoted.2. The inking performance of plate materialThe inking performance of plate material, especially the one wore out after being used for a long time. The progress of plate technology has greatly improved the quality of printing, to a certain extent to reduce the chromatic difference of the presswork, but whether it is rubber plate, resin plate or flexo, long-term wear will greatly reduce its inking performance. Therefore, it will frequently cause problems such as shallow imprinting, unsaturated ink layer. If in this case just add the printing pressure, rather fundamentally solve the problem, it will only lead to plate material further damage and chromatic difference, and carton compression resistance will be greatly reduced.3.Pressure balance, uniform printingThe speed and stability of printing can both lead to color changes. As the printing speed increases, the ink volume increases rapidly, the ink layer thickens and the color increases. On the contrary, when the printing speed decreases, the amount of ink is reduced, the ink layer becomes thinner, the ink is lighter, and the amount of ink is difficult to reach saturation. Therefore, in order to maintain a stable color, it is necessary to maintain a stable printing speed.The same goes for pressure control in printing. Too much pressure, the amount of ink is all, the printing is breezing. Too all pressure on the upper roller, the gap of roller larger, the amount of ink is too much, not only resulting in thick ink layer,hue change, but dot printing will cause paste, and solid field printing will cause creeping.4.Control paper material color, gluing amount, smoothness and other indicators Paper whiteness is included in spectrodensitometer measurement, so measurement and analysis of the chromatic difference among products have to remove the impact of paper color, because the customer will never forgive the chromatic difference caused by the paper factor. Therefore, control paper chromatic difference also become an important job. Especially in the current carton packaging market, the white paper is not used commonly, colored kraft paper, board paper accounted for a larger proportion. Printing on colored paper will produce the effect of “sunglasses”, which should be prevented in the prepress design.Paper smoothness, gluing amount will also cause carton printing chromatic difference. Paper with high oothness will be plane reflection, color will appear bright and light. On the contrary, rough paper will have ink layer diffuse reflection, hue will appear heavy. The gluing amount of the paper will affect ink adhesion, and the thickness of the ink layer directly affects the chromatic difference.5.Strict management system on standard color sample In general, the customer will deliver a standard color sample, if it is a newly developed product, the customer will also confirm a standard color sample before mass printing. Therefore, the customer's color is the standard, color management must be based on the sample color.1).Respect the customer's original standard, do not change without permissionNo matter how many times the plate material is changed, the technical parameters can not be changed, if possible, color density, chromatic difference and other standard items should be recorded into the spectrometer.2). Properly keep to prevent loss, damage or discolorationImproper storage of samples is easy to cause discoloration, once color changed, it will lose the significance of being standard. If used for guiding production, the consequences are unimaginable. Therefore, it is necessary to establish a strict management system to provide a good light-proof and moisture-proof environment.6. Record management Records not only enable product traceability, process records can also enable operations to be traced. According to the requirements of ISO quality management system, there are many kinds of records, which should be done according to document requirements one by one. The projects that really guide production operations and quality control are largely fixed. After each batch of cartons are finished, the ink ratio, viscosity index, printing number, machine speed, operation notes, product inspection and measurement data, even customer comments should be recorded in details. These are truly assets that are conducive to quality improvement and quality improvement.The printing process is variable, and these measures above can not totally ensure there is no chromatic difference. In order to do a good job in color management, and reduce the corrugated box printing chromatic difference, it also requires our crew operators, inspection personnel, management personnel to be careful in observation and adjustment, diligent summary and improvement innovation. In short, color management can achieve the goal of optimizing the carton printing quality.

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Printing crush forms and its effects

1.Printing crush formsIn the printing production , the cardboard is often crushed, giving rise to the problems such as unprinted patches and printing paste, reduction of the carton pressure resistance, which is a serious problem threatening the production quality. The cardboard crushing is divided into all-crushed, strip crushed and part crushed, we need to make a detailed distinction to the reasons.1).All crushed If the carton is found to be completely crushed, please check whether it is full-page printing on the surface. If not, the crush probably caused by paper feeding roller. If it is full-page printing, first we should release the printing pressure and then feed the paper. If the cardboard is not crushed, it demonstrates that the pressure of printing plate is too much,that’s why to crush the cardboard.2).Strip crushed This is one case of the part crushing, generally the pressure of pull rolls is too large, resulting in cardboard being crushed. At this time the crushed cardboard is in a strip state, and the width is the same with the pull rolls,, this kind is easy to distinguish.3).Part crushed The cardboard crushing area is where the printing pattern is, indicating that the reason for part crushed is the high printing pressure, the crushed size is the same with the printing pattern.Of course, too much die-cutting pressure will also cause cardboard crushed. And the cardboard crushed in terms of the press is probably the too much printing pressure. We should analyze according to actual situation.The cost impact of printing crush1. When cardboard crushed, it will directly lead to the expansion of printing dot, reducing the printing fineness.2. The crushing will result in the reduction of the carton compression value, generally giving rise to a 10% drop in the carton physical index.3. Printing crush is a production accident, in order to meet customer requirements with demand products, the carton factory will have to rework, which definitely increase the paper costs .

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The factors that feeding roller to crush the cardboard

1. Paper feeding modeThe conventional paper feeding mode of printing press is: there are three sets of all pull rolls in the front, that transfer the cardboard to the paper feeding rolls, and then the paper feeding rolls transfer the cardboard to the following pull rolls. Because the paper feeding roll is a solid state, the upper and lower has two respectively, when in normal production, the height of feeding roll gap should be about 0.3 mm less than the cardboard thickness, the gap can not be large or all, if the gap is too large or too all, the paper feeding precision can not be guaranteed, such as if the gap is too all, clamped too tight, cardboard will be crushed.If it is two sets of paper feeding roll mode, the advantage is of high feed precision, but the disadvantage is easy to crush the cardboard.The easiest thing to happen with two sets of feeding roll is1).The printing operator adjusts only one set of feeding roll, causing the second set to crush the cardboard.2).Inaccurate display of paper feeding roll gap will lead to misjudgment.2. Paper feeding roll pressure control system Conventional paper feeding mode: The upper roll jumps up and down in the process of paper feeding. During pressure control:1).Pressure control system is inaccurate, resulting in cardboard being crushed.2).High speed paper feeding with a high frequency, but easy to hit the feeding roll, affecting the feeding precision.Improved paper feeding mode: The gap between the upper and lower roll is fixed, so during pressure control:1) The feeding gap can be adjusted according to the thickness of the cardboard when the pressure is controlled.2) The feeding precision is stable.

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10 Problems to notice in graphic design and plate making

In carton factory, the corrugated carton printing problems caused by unreasonable graphic design and flexographic production often appear, which seriously affect the pattern and printing effect of the carton. Now we will look at the problems in graphic design and flexographic production.1. Avoid full-page printing When designing corrugated carton, we should first avoid full-page printing in water borne flexographic printing press. When designing corrugated carton with full page, because pressing roller touches corrugated board, pressure between the plate and pressure roller will cause huge damage to the compressive strength of corrugated cardboard, and the infiltration to paper by a large area of ink will also reduce the compressive strength of the cartons. The physical performance of corrugated carton after the full-page printing will lower about 30%. Therefore, designing graphics and text should be as simple as possible, and try to avoid printing graphics and text everywhere on the corrugated carton, not to mention full page printing. If some cartons need full page printing, color group can not be too much, and the printing pressure in the premise of ensuring the printing effect should be as all as possible. Large quantities of cartons should choose other printing process. The application of corrugated carton pre-printing technology in domestic corrugated carton industry is an ideal solution to full-page printing, and it can achieve multi-color accurate overlap.2. Reduce the number of overlap The more the number of overlap, the more decreased the carton compressive strength, so the overlap should be reduced as much as possible. In particular, all patterns of accurate overlap, because the water borne ink on the surface of the corrugated carton will seriously affect the effect of overlap edge, especially when the offset carton products for water borne flexible printing, overlap color should be changed according to water borne flexible printing process. The pursuit of green packaging and saving packaging is actively advocated by many international enterprises. Simple, lively and creative pattern design can not only express the information of packaging products, but also save packaging resources and reduce production costs. Therefore, in many corrugated carton packaging, reducing the number of overlap is conducive to improve physical performance of corrugated carton packaging. On the other hand, too much overlap will lead a poor color reduction effect on corrugated carton, the cost for overlap is also very high.3. Avoid all font printingFlexible resin plate for all text is no problem, but corrugated carton from the effect of publicity should try to avoid all characters. For example, the text below 50px can hardly be seen at a distance of more than 5 meters, thus losing the significance of promoting the products. Printing times of the Plate with all font will be greatly reduced, printing operation is difficult to deal with. Printing pressure is light, text is shallow, if increase the printing pressure, on the one hand, it will lead to dot deformation, text and lines appear obvious "edge effect", on the other hand, corrugated structure will be damaged to reduce the strength of the carton. Therefore, all font printing should be avoided for carton graphic design .4. Avoid ribbon printing (i.e. the same with mechanical direction of corrugated board)There are horizontal gradient lines on the patterns of some cartons. When printing, carton in this area is very easy to break because the stress is concentrated. The printing pressure will crush the flute, so the ribbon printing should be avoided.5. Use ink with strong saturation and coloring For some carton samples with bright colors, the ink color should be eye-catching. Because the color of corrugated board itself is quite dark, we should try to choose color saturation, strong coloring ink (such as bright red), otherwise, printed color and expected color will have a big difference. It is not realistic to assume that the color on the proofs will be the same as what you see on the monitor, or as the samples printed by the inkjet machine.6. Relax pressure of flexo on corrugated cardboardA design with a all gradient dot pattern should consider a high printing plate screen lines . In the flexo dot design, the factors of printing press precision should be considered, the pressure range of flexo on corrugated board should be relaxed, and the ratio between the screen lines of printing plate and the lines of anilox roller should be reasonably selected.7. Reasonable design of opening typeThe position of the hand hole on the carton should be designed in the middle as far as possible, and reasonable opening shape should be considered in the design.8. Avoid large differences in printing patterns on the same pageCarton layout design should avoid large areas of the field and dot printing on the same layout.9. To consider elastic deformation of flexible plateBecause the flexible plate is elastic, after installed on the plate roller, the plate will be bending along the circumference of the roller, yet almost not bending along the roller axis. This deformation will cause the size of the printed text to change. For those high-end printings, you must take measures to compensate, the best way is to change the size of print film. If there is a round pattern on the manuscript, it can be photographed by using a deformed mirror with the calculated compensation factor. The compensation factor is the reduction factor of the print film, that is, the percentage of the size of the print film should be reduced in the direction of printing.10.Make sure the sample is consistentThe sample should be kept the same in graphic and text design output, to avoid the output difference of different printers, which makes it difficult to test and judge.

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What should be prepared before carton printing?

1. Check the Process Sheet and Process InstructionAfter having the operation concept, we should check whether the preparation before printing is sufficient. First, to check whether the content of process sheet is complete, such as the notes on process sheet, generally include: printing model, specification, plate number, printing status, numbers etc., Second, to check whether the process instruction is complete. Printing process instruction is a very important process reference for processing before printing. Therefore, we must carefully review before printing.2. Check Sample CartonBecause the colors of carton are various, even the carton, the color can be varied from its nature color to other colors. That’s why even the same color that printed in the different kind of paper would appear differently. In this case, it is vital to check the cartons before printing.3.Check Parameters of EquipmentThe most important thing before printing is to check if the initial parameters of the equipment are correct. The initial parameters refers to whether the gap is reasonable when the equipment is to print the cardboard. We can have a better understanding about whether the gap in the following parts is adjusted properly, including front baffle, side baffle, paper feeding roller, inking roller, printing roller, slotting crush roller, scoring roller, we need to make sure these initial parameters are adjusted to zero before printing. 4 . Check the Ink 1) Hue Check● Use a scraper blade or color wheel to scrape a ribbon on the color paper, then compare with the sample color to determine whether the color is correct. Hue directly affects whether the color of the printed product is correct, which is the first important item of ink quality inspection.● The most objective method is to use the colorimeter. We scan the standard color with the colorimeter , and then scan the color scraped by a scraper, this two colors will form a density difference. But a lot of factories do not have colorimeter, therefore they can only observe with naked eyes, in this way, there is one thing in particular, due to the illuminant difference, inspection result can be greatly different, therefore the illuminance of fluorescent lamp is very important. Make sure to use fluorescent lamps. Some factories use xenon lamps, which will cause problems , especially on night shifts.2) Viscosity CheckIn flexo ink viscosity detection, we usually use Tushi cup and stopwatch, this is the simplest method, its advantages are easy operation and carrying, durable and low price. Of course, there is also a complex method, that is to the use torque viscometer, it is more scientific, being used for experimental calibration, but the actual operation is not very applicable.Requirements of Viscosity Test: a).Before the test, the ink must be mixed evenly;b).Make sure the measuring tool is correct;c). Try not to have foam on the measuring cup;d).Try to control the ink viscosity in 10~30 seconds (No. 4 cup). Generally, the general viscosity is about 24 seconds. 3) PH Value TestPH value is used to test the ink PH, which has a certain impact on the ink viscosity, and ink trapping. Generally, PH value tester is used for detection. PH value detection requirements: the probe should be cleaned, the calibrated button should be pressed before detection, and timely cleaning should be carried out after inspection. This kind of detection is very accurate.Some companies use PH test paper, this method comes with a problem,that is, some color can not be tested, because the PH test paper is detected by discoloration, once other ink sticks on the test paper, it will cause errors.4) Surface Tension TestThe surface tension test is conducted only when there are a lot of hard-to-interpret problems come out. This is not a regular way. Surface tension is measured by a surface tensiometer.5. Check the Plate The printing plate has three layers, the surface is a printing plate, the middle layer is a pad, the back layer is double-sided adhesive tape, the pad and the printing plate will both affect the quality of printing.1) The Hardness of the PlateThe key to check plate is to check the hardness, the surface hardness of 3-7mm resin plate is generally in 30-40 Shore hardness.2) Whether the base of test plate is roughGenerally rough base is caused by the following reasons:underexposure on the back, brush-out pressure and time are not enough, the time of using brush-out potions is too long, exposure is not uniform.Having burrs when the base is rough for printing.3) The surface of the printing plate is crackedThe reason is because the front exposure light distribution is not uniform, curly storage, printing plate is not stored in the dark room, printing plate is oxidized in the air. In the case of plate cracks, cracks will be stained with ink, bring bad effects on the presswork.4) Obvious cracks on the base The main reason is because the exposure time is too long, the base surface hardness is too high, it is easy to crack under a certain tension, so that affects the transfer of ink.5) Check the flatness of the plateBefore make-ready, we should pay great attention on flatness, a lot of people would add more pressure when the printing effect is bad, this is wrong idea. In this condition, we should first check whether the printing plate is flat.6. Check Anilox RollerAnilox roller inspection does not need to carry out very frequently, but must do on regular basis. A high-precision test usually takes two aspects: the amount of ink, and to use a luminous magnifying glass to take a picture.1) Use a professional camera, placed on the anilox roller to film, then it can show the proportion of mesh blocking.2) You can use 60-100 times of luminous magnifying glass, the magnifying glass is placed on the roller, the focal length is adjusted, and the digital camera is placed on the magnifying glass to shoot, it also can obtain the real image of mesh . Once a month or twice a month is acceptable.3) Load the obtained mesh image into the computer, compare the blocking ratio, and judge whether to clean the pattern roller according to the blocking situation.The new images will be shiny, 10% of the mesh blocking will be blurry, 20% will be dark.4) Scraper inking, if 10% blocked, it should be cleaned immediately, glue roller inking, if 20% blocked, it should be cleaned immediately. It is recommended that you do a simple cleaning in every shift, as cleaning becomes more complicated when the blockage reaches 10% or 20%.Simple cleaning is to use a brush and washing powder, if done every day, then the monthly photo can be completely neglected. The quality of presswork will be very good. There is one thing to remind,that is, different roller with different brush. If ceramic roller, steel brush should be used, if steel roller, then we choose a copper brush, otherwise the roller will be damaged.7. Cardboard InspectionHere are six things to watch out in cardboard inspection: flatness, temperature, humidity, paper PH, ink absorption, paper surface tension.

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Attention! Problems to Prevent during Corrugated Carton Printing.

Problems that need to be reminded during corrugated carton printing are as follows:1. Ink Color Should be Eye-Catching Because the color of corrugated board itself is quite dark, when choosing the ink colors, those who have strong saturation and coloring power (such as bright red) should be given priority. Or there will be quite different between the chosen color and the desired color. 2 .Avoid Printing Small Words As corrugated carton printing, from the effect of publicity products, font size should be well selected. Words less than 2cm in size are almost invisible at a distance of more than 5m, thus losing the significance in promoting products. 3 .Avoid Full Plate Printing When printing in full plate or surrounding, in addition to pressing roller on corrugated board has the effect of pressure, the ink has a drench effect on the surface of the paper, which will reduce the compressive strength of corrugated carton. Therefore, the graphics and texts on corrugated cardboard should be as simple as possible, and try to avoid printing on the entire surface of the box, nor full plate printing color. 4 .Avoid Ribbon Printing (Along the direction of corrugated board mechanical)Some decoration designers due to the lack of knowledge of printing process, the carton printing patterns designed have some horizontal gradient lines. When printing, the printing pressure crushes the flute. Stress concentration will occur in this area of the carton and it will be easily broken. 5 .Minimize the Printing Pressure In order to ensure the quality of carton printing, and reduce the impact of corrugated carton strength, printing pressure should be minimized, the ink should be selected as fast drying oil ink.Secondly, the printing surface and horizontal scored line should be maintainedat a distance of more than 15mm. 6 . Keep Ink Viscosity Stable Ink viscosity is the main index that needs to be controlled in corrugated board printing. Due to the ink solvent volatile in the printing process, the base viscosity will rise, in order to maintain the stability of ink viscosity, ink stabilizer should be added at every half an hour to one hour , the amount should be 1% to 2%. 7 . Keep the Feeding Performance Stable In addition to keep printing press running speed stable, manual feeding point needs to be fixed. For the bad flatness of the cardboard, it should be properly handled, such as reflexed the cardboard along horizontal pressure line side (or both sides), with hand pressure etc.to keep paper guide clearance consistent. These are important link that related to the stable operation of cardboard, but also an important method to prevent "plate dislocation". 8 . To Keep ink transfer steady Has to keep printing speed balanced and stable. Because the printing speed is related to the ink transfer, it must be operated at an average speed, neither fast nor slow. Also keep feeding paper one by one, avoiding skip feeding. Only in this way can the ink printing press keep a stable ink transfer, which is important to maintain the color stability of ink printing.9 . Minimize the Number of Overprinting The more overprinting, the more serious that corrugated carton compression strength decreased.

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In Plum Rain Season,How to Deal with the Blur and Deinking of Carton Printing?

It is inevitable that plum rain season comes every year, while it is the most likely to appear blur and deinking during carton printing in this rainy season. The main reason is that corrugated board affected by high humidity weather, resulting in soft cardboard, so the printer has to increase the pressure.When the ink transfer to the paper, due to the humidity of corrugated board, print blur is more likely to appear due to the enlarged fonts.In addition, high humidity of corrugated board will also lead to deinking on the printing surface . In this way, how to prevent such situation?1 . Adjust Printing Pressure Feeding gap must be well controlled during the rainy days, thickness of the cardboard should be less than 0.4mm.When the air humidity is large, the cardboard itself is softer than that in the dry air. If the feed gap is too tight, the cardboard will be crushed, then the printing pressure must be increased, so it is easy to cause the paste and deinking. If to reduce the feeding pressure, the hardness of the cardboard can be ensured, printing pressure can be decreased, so as to ensure the clarity of printing. 2 . Printing InkHigh ink viscosity is also an important factor resulting in deinking and blur. Therefore, in the rainy season, the viscosity of the ink must be reduced, while the concentration of ink color should be increased, so the drying speed will be accelerated, avoiding the blur and deinking due to the ink itself.--If there is Copyright Dispute, Please Contact us to Delete.

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Discussion on Flexo Printing Technology of Corrugated Board

With the development of social economy and the improvement of national living standard, people paymore attention to the perfection of commodity packaging. Corrugated carton packaging with its unique in the whole goods packaging industry accounts for a growing proportion, andthe key technology of corrugated carton is ink printing. Thisarticle will discusshow to improve the quality of ink printing by improving the equipment. 1、 The Treatment ofPrinting“unprinted patches” Unprinted patches in the corrugated carton production is the most common problem that is difficult to be eliminated, the reasons are:(1) poor ink absorption performance ;(2) printing plate dirty;(3) scraps of paper, dust on the cardboard.The conservative way to deal with these problems is to change the box manually or increase the frequency of manual erasing. These methods will play an objective role to some extent, however, the improvement effect after the box changed is not obvious, and easy to cause efficiency decline; Erasing can also cause water, electricity, artificial waste.In the process of equipment installation, maintenance and management, through long-term observation and analysis, the author believes that the key to solve the problem of printing unprinted patches lies in dust removal, and the main source of dust is generated by single-blade paper separation. Based on this situation, two years ago, the author has respectively installed electrostatic suction dust absorption device after the computer crosscutting knife and printing machine feeding .Use a hair dryer in front of the computer crosscutting knife, to blow out the paper scraps hidden in pits when the single blade cutter is divided into paper, and then use the electrostatic air suction and dust absorption device to suck away the paper scraps at the paper receiving frame after the computer crosscutting knife. At the gap between the feed apron and the feed wheel in the feed section of the printing machine, electrostatic dust is used to absorb the dust on the board, so as to keep the printing surface clean and dust-free. In this way, when the product enters the printing roller, there is no obstacle to ink loading and ink absorption is even.After such improvement, the printing effect of the product has been greatly improved, and the phenomenon of unprinted patches caused by dust has been fundamentally overcome. 2、 TheTreatment ofOverprintingLocationMoving Now commodity packaging pays more attention to the artistic quality and three-dimensional sense of patterns, so that consumers can feel the perfection of commodities purchased from the outer packaging. To achieve this purpose, multi-colored printing must be adopted in packaging printing, that is, multi-colored overprinting.In the overprinting process, often appearsoverlapping betweenthelattercolor and theformercolor or position dislocation, resulting in printing patterns can not reflect the product packaging design effect, or even widely divergent, completely destroyed the image of the product. In view of this special problem, our factory after a period of in-depth investigationand research on the spot , from electronic control reaction speed to mechanical tolerance accuracy, carried outadetailed calculation, improvedthe existing equipment,andset up relevant equipment maintenance measures.(1) . Improve thePrecision of PrintingDrumPhasePositioningThe phase positioning of the printing drum is controlled by encoder and counter. If the accuracy of counter is too low, the position of encoder will be inaccurate. When printing, the position will be dislocated, generally, counter reaction speed is 3K, but the positioning error is plus or minus 1mm. After discussion with Taiwan electronic control company, 5K counter was produced, which reduced the positioning error of printing drum to + / - 0.4mm.(2).RegularlyLubricate andInspect theTranissionMachineryIn the process of paper feeding, if the tranission machinery can not maintain a good and ooth operation, each time the position of the cardboard will change, resulting in printing and overprinting dislocation. Therefore, it is very important to maintain and test the equipment correctly. We have developed a daily pre-startup test running checklist, which includes lubrication maintenance, and the wear limit of the paper feeding wheel, paper feeding ring , those unqualified must turn over grinding, change the feeding roll or replacement, so as to overcome the dislocation, oblique position and other phenomena of cardboard in the process of transport.(3) . AdoptSuctionFeedingSystemThe traditional printing machine uses the upper printing, which can only use the paper wheel to transfer the cardboard, but the new printing machine uses advanced technology of the lower printing, the upper suction to transfer cardboard. Suction feeding paper uses wind power to adsorb the cardboard on the tranission wheel, its suction is even, not dislocation, and oblique position, and it will suck the curved board to flat, enabling an accurate target on printing, making ink more even and flat. 3、TheProblem of Ink Feeding In addition to paper and offset problems, there is also the technical problem of the ink roller.The inking rollers are all anilox rollers. In high-standard carton printing, anilox rollers used above 250lpi, its mesh holes are most likely to be blocked by ink residue, resulting in uneven inking, insufficient ink quantity and shallow ink. The traditional method is to use water to clean the ink roller, but no matter water scrubbing the ink roller or detergent scrubbing method, the effect is not ideal. A new ink roller used less than a month, the effect is not as good as before.After a long period of trial , we find that the following methods can effectively solve the problem of poor ink printing:(1) . Add filter net in the ink bucket to prevent ink particles from entering the ink roller.(2) . Regular (generally half a month) use anilox deep cleaning agent, cycle cleaning.(3) .Wash the ink roller with dripping water in circulation every day after work, and dialyze the mesh hole of the ink roller with 60-100 times magnifying glass. No ink residue is allowed. If part of residual ink exists, immediately scrub it with deep cleaning agent.Through the above methods, the ink effect on the ink roller can always maintain good. The above printing technical problems are crucial to the quality of carton products in actual production. Through the understanding and improvement of equipment, as well as good maintenance, we can produce products that satisfy customers and improve the comprehensive benefits of the enterprise.

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What’s the difference between offset and Carton High Graphic printing?

Help you to making right choice. Although both methods use wet ink and printing plates, these two printing processes are quite different. Technically, offset printing can refer to any printing technique that uses a printing plate to transfer an image to an intermediate carrier and then onto the printed substrate. Whereas flexo transfers ink from the plate directly to the substrate.Flexo and offset are both popular, but they perform their tasks differently. It is important to understand what roles they perform and have a clear understanding of both types of printing process. The type of press to use depends on the final product and quality required, as well as volumes and substrates.Difference 1: Plates As the name suggests, flexo printing utilises flexible plates for a rotary printing process. The plates are made from a photopolymer compound and are flexible enough to be wrapped around a printing cylinder. The relief image on the plate is fixed via a laser image-setter and the polymer in the ‘non-print’ areas is washed away in a processing unit, where it is dissolved into a solvent or water solution. Ink is transferred from the ink well via a rotating ‘anilox’ roller onto the flexo plate. A separate printing station & flexo plate is required for each colour to be printed. The image is then printed directly onto the substrate. The printing plates are quite durable and if stored correctly, can be re-used several times, before they eventually need to be replaced. For offset printing, again as the name suggests, ink is transferred (offset) via a series of rollers onto the printing plate. This can be either a flat-bed or rotary process – depending on the type of offset press. The plate is usually made of aluminium. The complete wet image (either single colour or multicolour) is then transferred onto a ‘blanket’ and in turn onto the substrate, before drying.Difference 2: Ink Offset printing usually consists of four ‘process’ colours; cyan, magenta, yellow and key (which is black). Each colour has a dedicated printing station. Any spot colours are made from a combination of the process colours. Ink can be water based or UV curable. Although process colours are also used in the flexo process, additional print stations tend to be used for spot colours. Spot colours can be supplied pre-mixed, or can be mixed in-house, as required. Flexo inks can also be water-based or UV curable. Solvent based inks can also be used. UV inks enable higher running speeds and can be left in the press at the end of the day, without the need to empty & clean each print station. Water based inks need to be removed from the press, when it is not in use – to prevent ink from drying on the rollers & in the ink trays.Difference 3: Types Of Materials To Print On Offset printing machines can print on materials such as; paper, metal, cardboard, cellophane and vinyl. The printing surface must be flat and ooth. It is excellent for printing newspapers, books, magazines, stationery, posters, brochures and so on. Generally, to print onto both sides of the substrate will require a second pass. Similarly, any die-cutting, slitting, folding, creasing, laminating, etc is done as a secondary, off-line process.Flexography is used on both absorbent and materials, for example, cellophane, foil, cardboard, fabric, plastic, metal etc. It is mostly used for packaging; envelopes, retail bags, wallpaper, paper, newspapers, sweet wrappers, labelstock and so on. The main difference with both processes is that offset printing is only done on flat surface while Flexographic printing can be used on almost any substrate with a flexible surface. Flexo printing can achieve high speed production and many presses have multiple converting options integrated into the press, enabling a single pass operation.Making The Right Choice Both Flexographic and offset machines have their advantages. Flexography is excellent for high speed production and overall quality. It is great in efficiency in many ways and is generally appropriate for most large-scale printing tasks. In the label printing sector, most businesses prefer flexographic printing because of its adaptability and economy of scale. When looking for a printing solution, look for one with the future in mind, and invest in the printing technology of the future. One current trend for flexo is for it to be combined with digital printing technology to produce powerful hybrid solutions that outperform most traditional offset presses.Flexography beats offset printing in many circumstances because of its flexibility & productivity benefits. A flexographic press is a sound, long term investment and is adaptable enough to accommodate and integrate a wide range of in-line processes, including new digital technology.--If there is Copyright Dispute about the content, please Contact us to Delete.

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The Impact of Environmental Humidity on Corrugated Board and Carton Strength

1. Corrugated Board Corrugated board is glued by box board and corrugated original paper, which is a composite board used to manufacture corrugated cardboard box. Raw materials of corrugated board are mostly plant fiber raw materials, although different in types, its chemical composition is mostly cellulose, hemi cellulose, lignin and a all amount of starch, pectin, resin, etc., and cellulose is the primary chemical composition of plant fiber, accounting for more than 50% of all kinds of paper raw materials. Cellulose is a polymer compound, generated by glucose polymerization, each glucose radical ring contains 3 alcohol hydroxyl groups, so that cellulose molecules and molecules have a strong hydrogen bond, cellulose is very easy to absorb water and swelling, the fiber internal cell wall structure becomes relaxed, cohesion decreases. This is the micro-reason that corrugated carton are sensitive to humidity changes .Therefore, the variety of environmental humidity will have a great impact on the performance of corrugated board. 2.Corrugated board strength under different humidity conditions (1) . Experimental EquipmentConstant temperature and humidity box, corrugated board cutting device, electronic compression tester, a test equipment used for corrugated board edge pressure strength and adhesion strength , piercing strength tester, used for corrugated board piercing strength .(2). Experimental MethodsThe experimental raw material is AB five-layer corrugated board provided by carton factory, with an average thickness of 8.00mm. Sampling is conducted according to GB/T 450-1979. Test specimen under temperature is 20 ℃, humidity is 20%, 40%, 60% and 80% respectively under the condition of 24 h, according to the GB/T 6546-1998 corrugated cardboard marginal pressure strength measurement, GB/T 6548-1998 corrugated cardboard gluing strength measurement and GB/T 2679.7-2005 board puncture strength measuring method.(3). Experimental ResultsTest the edge pressure strength, adhesion strength and puncture strength of corrugated board under different humidity conditions. The experimental data are shown in table 1. (4). Analysis of ResultFrom the data of table 1, it can be seen that the edge pressure strength and adhesive strength of corrugated board decrease with the increase of environmental humidity; When the relative humidity is 20% ~ 60%, the puncture strength increases with the increase of humidity, and decreases when the relative humidity exceeds 60%. When the relative humidity increased from 20% to 40%, the strength decreased significantly, and the relative humidity decreased by 16.4%. When the relative humidity increased from 60% to 80%, the adhesive strength decreased by 18.5%, and the puncture strength increased by 775% when the relative humidity increased from 20% to 40%. Environmental humidity on corrugated carton strength 1. Corrugated carton compression strength under different humidity conditionsCorrugated box compressive strength is mainly affected by corrugated board edge compression strength and adhesion strength. In different humidity conditions, corrugated board edge compression strength is obviously different, therefore, corrugated box compressive strength is also affected by environmental humidity. The compressive strength of corrugated cartons under different humidity conditions is shown in table 2. As shown from the data in table 2, the compressive strength of corrugated cartons decreases with the increase of environmental humidity. This is because as the rise of environmental humidity, the moisture content of paper board is increase, the cellulose in corrugated board became loose after absorption of moisture, and moisture absorption rate of linerboard and inner linerboard are different , resulting in different rate in the process of the pressure on the deformation, so the compressive strength of corrugated carton decreased as the rise of environmental humidity. Corrugated carton no matter in production or in the process of circulation will be affected by the environmental humidity. Therefore, reasonable control in the production, warehouse storage and environmental humidity during transportation, will have a positive impact on the use of corrugated board, carton. In addition, the production of corrugated board raw materials with moisture, moisture resistance agent has gradually become a developing direction to a new type corrugated cardboard box .

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How Carton Die Cutting Line is not Straight, Carton Die Cutting Size Changes, and Rotary Die Cutting Line, What’s the Reason?

Die Cutting Size is Aabnormal When the die cutting rubber pad circumference changes, the carton die cutting size will also change, so when the die cutting rubber pad wear too much must be grinding or replacement, in order to ensure the accuracy of die cutting size. Thus, in the process of die-cutting production, the selection of die-cutting rubber pad is very critical, in the purchase of die-cutting rubber pad to take into account the life and quality. Die - cut rubber pad wear faster, your precision error probability is greater. Therefore, the operation should be as far as possible to reduce the die-cutting pressure, which is conducive to the life of the mold and plastic pad. Rotary Die Cutting Scoring Cracks Die cutting part of the adhesive pad wear will lead to uneven surface, die cutting pressure will have a big or all, so there will have scoring cracks in rotary die cutting. When dealing with the scoring cracks problem, we should combine the concrete situation analysis. Such as:1. some of the scoring cracks and some of the non- scoring cracks, that is because the pressure system is not uniform, die cutting products when vibration caused by the scoring cracks problem caused by machine vibration ;2. If all line scoring cracks , it is too much pressure caused

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How to plan corrugated carton production factory-Carton Box Production

Outline of Manufacturing Process and Materials Utilized The manufacture of corrugated packaging can be roughly classified into two processes: the containerboard combining process, which glues one or more sheets of fluted corrugating medium to one or more flat facings of liner board; and the box manufacturing process, which is used to assemble the corrugated sheets into boxes. Figure 1 depicts the typical manufacturing process flow and the auxiliary facilities that are used at a corrugated packaging plant. Figure 1 Overview of Manufacturing Process Flow for Corrugated Packaging 1. Printing Inks Printing for corrugated packaging has evolved from the use of oil-based inks to quick drying inks and now to flexo inks, which are most common. Theuse of oil-based inks has almost completely ceased and even quick drying inks are now utilized only occasionally. The special characteristics of each type of ink are shown in Table 2. Table 2 Characteristics of Printing Inks Used for Corrugated Packaging 1.Printing Process – Printer Slotter The printer slotter performs printing, scoring and slotting. There are two types of printer slotter: one type that utilizes flexo inks and another type that utilizes quick drying inks. 2. Printing and Forming Processes – Flexo Folder Gluer The flexo folder gluer first performs printing onto the surface of box blanksthat have been scored lengthwise. Next, the machine performs slotting andwidthwise scoring, finally gluing the manufacturer’s joints together to formboxes. 3. Punching Process- Die Cutter The die cutter utilizes cutting dies to punch out specific shapes from printedbox blanks. Rotary die cutters and platen die cutters are most commonlyutilized, however, die cutters are also used in combination with flexoprinting machines. 4. Joint AdhesivesFigure 4 depicts the methods used to glue the joint when manufacturing the most common type of general-purpose corrugated box, as shown in Figure 3(type 02 – refer to JIS Z 1507). Currently, of the methods shown below, An extremely efficient gluing method (glue joint method) employing high strength adhesive is most widely utilized.The machines that are used to form boxes with this glue joint method are called “folder gluers”. Folder gluer machines generally utilize vinyl acetate emulsion adhesives, in particular, those adhesives containing di-n-butyl-phthalate and xylene (or toluene), in order to improve heat resistance, cold resistance and drying speed. However, new adhesives have recently been introduced to the market, which contain significantly reduced amounts of di-n-butyl-phthalate in order to meet the standards prescribed under the PRTR Law. Therefore, it is expected that, in the near future, the adhesives used shall make the transition to substances that no longer employ Class I Designated Chemical Substances. Figure 3 Forming of a Corrugated Box Figure 4 Method of Forming of a Corrugated Box --If there is Copyright Dispute about the content, please Contact us to Delete.

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Rotary Die Cutting vs. Flatbed Die Cutting--How to Choice?

Now the world corrugated packaging industry USES the most two die –Rotary die cutting and flatbed die cutting Many companies are confused, so how to make a choice?Now it’s time to take a closer look at the two die cutting methods available - rotary die cutting and flatbed die cutting. Which one is right for you? The BoxMaker corrugated plant has both available in-house, and each method is used regularly in different situations. The working Speed between Rotary and FlatbedThe Rotary Die CuttingIt is usually one of the units of flexo printing machine,it’s called Die-cut unit. Speed often depends on the type of carton produced and die cutting type.The normal production speed is 150-250 piece/min,some machine can reach 350 piece/min. Flatbed Die Cutting To be exact, there are 3 types in the market, one is manual, Semi-automatic and full automatic. The speed of the device in type 3 is completely different.the Manual speed around 30 piece/min, semi-automatic is around 60 piece/min.Full automatic die cutting max speed can reach 100-120 piece/minCutting Dies Cutting dies are long lasting, quality structures and present a one-time charge for your company. The maintenance, storage, and cleaning of all dies is covered in the initial price you pay.Rotary steel dies are more expensive than flatbed dies because the wood for a rotary die is circular in shape, and the method for making these is more extensive. Yet, looking at the price of the steel die alone is not enough information to make an informed decision.There are many factors to consider when choosing the best method for your packaging needs. Our estimating team will take into account the following factors to determine the right direction for you and your organization:How many will you be ordering? Rotary steel dies can be 30-100% more expensive than a flatbed die, but the rotary machinery can run more pieces at once due to a larger blank size and faster speed. So, while the initial steel die may cost more, a lower per-each price can offset the die cost quickly.Will you be buying multiple orders on a regular basis, or is it a one-time purchase? If you are purchasing a specific product for a one-time promotion or a single distribution, then a less expensive flatbed die may be the best way to go. But, if you have regular usage of a specific product and plan on purchasing multiple orders of a particular package, the rotary machine will offer a lower piece price and will quickly offset the higher die cost.Example:Flatbed die charge: $800, .25 cents per box for a 5,000-piece orderTotal investment after 1 order: $2050Total investment after 3 orders: $4550Total investment after 10 orders: $13,300Rotary die charge: $1400, .19 cents per box for a 5,000-piece orderTotal investment after 1 order: $2350Total investment after 3 orders: $4250Total investment after 10 orders: $10,900As you can see, rotary die might be more expensive, but you actually start saving money after just 3 orders!How large is your product? The rotary machine may be fast, but it doesn’t handle all pieces well. If your blank size (piece of corrugated product laid flat, before folding or gluing) is less than 15” in width or length, we will need to cut it on the flatbed die cutter. On the opposite spectrum, the capabilities for die cutting large blanks are limited on the flatbed machine. With a maximum blank size of 66” x 85” on the rotary die cutter, it can handle a lot of larger format pieces, and can cut out more at one time. The flatbed machine has a maximum blank size of 41” x 55”.How intricate is the design? The rotary can handle big designs, but not necessarily intricate ones with tiny cut-outs, tight radius on corners, and slit scores. Since the rotary is a giant wheel rolling over the corrugated, the cutting isn’t quite as precise as the flatbed die cutter. Our structural designers have the expertise to know ahead of time which machine will be best suited for your product.Is your corrugated packaging printed? The rotary press can print up to 3 colors AND die cut at the same time. This means that if your product needs to be die cut on the flatbed, it will need to get printed on another machine first. This adds to labor costs, and ultimately can lead to a higher price for you. Whenever possible, it makes sense to pay more upfront for the rotary die so you will see the savings from this investment down the road.As you can see, selecting the correct die cutting method is not a “cut” and dry decision! We take great care in guiding you to the best solution for your specific needs.--If there is Copyright Dispute about the content, please Contact us to Delete.

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Treatment of Contaminants - Dioxins

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredNote: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation;and number of print color change operations. Dioxins[Calculation Procedures]①Annual quantity of dioxins in exhaust gases released= quantity of exhaust gases* × measured quantity of dioxins in exhaust gases ×number of daily hours operation × number of days operation②Annual quantity of dioxins in incinerated ashes transferred= quantity of incinerated ashes released × measured quantity of dioxins inincinerated ashes[Calculation Examples]<Input Data for Calculations>*TEQ: As a variety of different dioxins are produced, the quantity of dioxins has beenconverted tothetoxicequivalencespecifiedby2,3,7,8tetrachlorinateddibenzo-para-dioxin.<Calculation Results>①Annual quantity of dioxins in exhaust gases released= 1,180×2.0×10-6 × 8 × 20 × 12 = 4.53mg-TEQ / year②Annual quantity of dioxins in exhaust gases released= 21 × 10 6 × 1.1 × 10-6 = 23.1 mg － TEQ / year--If there is Copyright Dispute about the content, please Contact us to Delete.

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Treatment of Contaminants - Ethylene Glycol

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable toutilize either: industry average values, nominal values or the standard values setby machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations.Ethylene Glycol Shown below are the flows for the release and transfer of ethylene glycol.Ethylene glycol is contained in the quick drying inks used during the conversion process and is present in wastewater subject to treatment. The quantities both released and transferred can be calculated by following the procedures described below.Figure 10 Flows for Ethylene Glycol Released and TransferredThe methods used for the cleaning and final treatment of printers that utilize quick drying inks will vary, depending upon the characteristics of the inks and the specifications of each machine. Therefore, the various treatment methods are classified as shown in (1) - (3), below.(1) Wipe-off Method: used for conventional roll transfer type printers and conventional spray type printers. After excess ink has been wiped off the printers with waste cloths, the materials used for cleaning are disposed of as industrial waste.(2) Industrial Waste Treatment Method for Waste Liquids: the waste inks resulting from color change processes and the wastewater from ink clean up are stored indrums, then disposed of as industrial waste, as is.(3) Wastewater Treatment Method: the printing process utilizes washable quick drying inks. After wastewater is treated by a standard wastewater treatments ystem, the wastewater is separated into liquid wastewater and solid waste. Inthe event that an activated sludge treatment is performed as a tertiary treatment,then the wastewater will be fully broken down into water and carbon dioxide.Therefore, the quantity of ethylene glycol released will be "0". Annual quantity handled Annual quantity released or transferred [Calculation Procedures]①Quantity of ethylene glycol handled = annual quantity of quick drying inkhandled × ethylene glycol content②Wipe-off Method: quantity of ethylene glycol transferred in waste= quantity of waste per color / cleaning operation × number of daily color changes×number of days of operation③Industrial Waste Treatment Method for Waste Liquids: quantity of ethyleneglycol transferred in waste = quantity of waste per color / cleaning operation× number of daily color changes× number of days of operation④Wastewater Treatment Method: quantity of ethylene glycol released towastewater = quantity of waste per color / cleaning operation × number ofdaily color changes × number of days of operation [Calculation Examples]<Input Data for Calculations>Note: Figures in red font represent industry average values / nominal values- Quantity of ink handled: 6,000 kg / year (wipe-off type: 3,500 kg / year)- Ethylene glycol content: 30%- Quantity of ink per disposal, per color: ② 350 g / disposal; ③ 50 g / disposal;④ 126 g / disposal- Number of color changes: 40 changes / day (wipe-off type: 20 changes / day)- Number of days of operation: 20 days × 12 months = 240 days / year<Calculation Results>①Quantity of ethylene glycol handled = 6,000 kg / year × 0.3 (3,500× 0.3) = 1,800 kg / year (1,050 kg / year)②Wipe-off Method: quantity of ethylene glycol transferred in waste = (350 /1,000 ) × 0.3 × 20 × 20 × 12 = 504 kg / year③Industrial Waste Treatment Method for Waste Liquids: quantity of ethyleneglycol transferred in waste = (50 / 1,000 ) × 0.3 × 40 × 20 × 12 = 144kg /year④Wastewater Treatment Method: quantity of ethylene glycol released towastewater = (126 / 1,000 ) × 0.3 × 40 × 20 × 12 = 363 kg /yearNote: In the event that the wastewater from procedure ④, above, receives tertiary treatment using an activated sludge treatment method, then complete decomposition would occur. Therefore, the quantity of ethylene glycolreleased would be determined as "0". If the wastewater is not treated using an activated sludge treatment method, then a slight amount of ethylene glycolwill be transferred along with the residual water, to the dehydrated waste(although most of the ethylene glycol is released to the wastewater itself).This miniscule quantity of transferred ethylene glycol is difficult to measureand is estimated as being only a few % of the entire quantity released.Therefore, for the purposes of the calculations above, the entire quantity ofethylene glycol is considered as being released to the wastewater, with none ofit being transferred to the dehydrated waste. --If there is Copyright Dispute about the content, please Contact us to Delete.

1108 0

Treatment of Contaminants - Toluene

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations. Toluene Figure 8 Flows for Toluene Released The flow of toluene released from joint adhesives used during the conversion process is the same as the flow of xylene described in section 2, above). Annual quantity handled Annual quantity released or transferred [Calculation Procedures]①Annual quantity of toluene handled=②Quantity released to atmosphere = Annual quantity of joint adhesive handled × Toluene content[Calculation Examples]<Input Data for Calculations>Annual quantity of joint adhesive handled: 22,000 kg / yearToluene content in joint adhesive: 5%<Calculation Results>①Annual quantity of toluene handled = 22,000 kg / year × 0.05 = 1,100 kg / year=1.1 t / year②Quantity of toluene released to atmosphere = 22,000 kg / year × 0.05= 1,100 kg / year = 1.1 t / year --If there is Copyright Dispute about the content, please Contact us to Delete.

1219 0

Treatment of Contaminants - Xylene

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations. Xylene Shown below are the flows for the xylene released. Xylene is contained in the joint adhesives used during the conversion process and is also used as an additive for boiler fuel. The quantity released can be calculated by following the procedures described below. Figure 7 Flows for Xylene Released [Calculation Procedures] Annual quantity handled Annual quantity released or transferred ①Annual quantity of xylene handled＝ annual quantity of kerosene handled × density × xylene content ＋ annual quantity of joint adhesive handled × xylene contentNote: 99.5% of xylene contained in kerosene is decomposed through combustion.The entire quantity of xylene contained in joint adhesives for combining is released to the atmosphere during the drying process.②Quantity of xylene released to atmosphere = Quantity of xylene in kerosene ×+ non-decomposition rate + annual quantity of joint adhesives handled ×xylene content[Calculation Examples]<Input Data for Calculations> <Calculation Results>①Annual quantity of xylene handled = 9,240* + 22,000 × 0.05 = 10,340 kg②Quantity of xylene released to atmosphere = 9,240 × 0.005 + 22,000 kg / year× 0.05= 1,146 kg / year--If there is Copyright Dispute about the content, please Contact us to Delete.

993 0

Treatment of Contaminants - Di-n-butyl-phthalate

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Di-n-butyl-phthalateShown below are the flows for the release and transfer of di-n-butyl-phthalate.Di-n-butyl-phthalate is contained in the joint adhesive used during the conversion process and is present in wastewater subject to treatment. The quantity transferred can be calculated by following the procedures described below. Figure 9 Flows for Di-n-butyl-phthalate Released and Transferred Annual quantity handled Annual quantity released or transferred[Calculation Procedures]① Annual quantity of di-n-butyl-phthalate handled= annual quantity of joint adhesive handled × di-n-butyl-phthalate content②Quantity of di-n-butyl-phthalate in the product= production volume of glue joint type corrugated × quantity of joint adhesive e applied × di-n-butyl-phthalate content of joint adhesive③Quantity of di-n-butyl-phthalate in corrugated waste= production volume of glue joint type corrugated × quantity of joint adhesive applied × percentage loss during the conversion process (glue joint type) ×di-n-butyl-phthalate content of joint adhesive④Quantity of di-n-butyl-phthalate from raw wastewater released from thewast ewater treatment process =①－(②+③)⑤Quantity of di-n-butyl-phthalate in the sludge discharged from the wastewater treatment process = ④⑥Quantity of di-n-butyl-phthalate transferred in waste = ⑤[Calculation Examples]<Input Data for Calculations>Note: Figures in red font represent industry average values / nominal valuesProduction volume of glue joint type corrugated:17,859,000 m2 / yearPercentage loss during the conversion process (glue joint type): 1%Annual quantity of joint adhesive handled: 13,800 (kg / year)Di-n-butyl-phthalate content of joint adhesive: 7.3%Quantity of joint adhesive applied (glue joint type only, including one-touch gluer):0.75 g / m2 = 0.00075 kg / m2<Calculation Results>① Annual quantity of di-n-butyl-phthalate handled: 13,800kg / year × 0.073=1,007.4 kg / year(Annual quantity of joint adhesive handled × di-n-butyl-phthalate content)②Quantity of di-n-butyl-phthalate in the product= 17,859,000 m2 / year × 0.00075 kg / m2 × 0.073 = 977.8 kg / year(Production volume of glue joint type corrugated × quantity of joint adhesive applied × di-n-butyl-phthalate content of joint adhesive)③Quantity of di-n-butyl-phthalate in corrugated waste= 17,859,000 m2 / year × 0.00075 kg / m2 × 0.01 × 0.073 = 9.8 kg / year(Production volume of glue joint type corrugated × quantity of joint adhesive applied × percentage loss during the conversion process × di-n-butyl-phthalate content of joint adhesive)④Quantity of di-n-butyl-phthalate from raw wastewater released during the wastewater treatment process = 1,007.4-(987.6) = 19.8 kg / year{① － (② + ③)}⑤Quantity of di-n-butyl-phthalate in the sludge discharged from the wastewater treatment process = ④⑥Quantity of di-n-butyl-phthalate transferred in waste = ⑤ = 19.8 kg / year --If there is Copyright Dispute about the content, please Contact us to Delete.

1005 0

Equipments

Corrugator & Wet-End

Layers

Width

Speed

Corrugator Dry-End

Layers

Width

Speed

Corrugator Related Machine

Roll Stand

Pre-Heater

Single Facer

Corrugating Roll

Glue Kitchen

Splicer

Guiding System

Double Facer

Sheet Presser

Corrugator Conveying Belt

Engery System

Slitter Scorer

Cut Off

Stacker

Process Control System

Printer Slotter Die-cutter

Machine Transfer Way

Sheet Transfer Way

Printing Way

Graphic

Flexo Folder Gluer

Driven Way

Sheet Transfer Way

Printing Way

Digital Printer

Printing Way

Printing Ink

Printing Related

Conveyor system

Pre-feeder

Printing Unit

Mold Making

Stacking

Complete in-line exit

Flatbed Die-Cutting

Manual

Semi Automatic

Automatic

Folder Gluer

Operate Way

Special Function

Stitching Machine

Operate Way

Strapping Machine

Operate Way

Conveyor System

Conveyor Function

Stacker

Winding Equipment

Waste paper Baler Machine

Robot Palletizer

Box Making Machine

Parts

Blades

Additive

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