The domestic corrugated box market is becoming increasingly competitive, and product prices are the main means of competition. How to seek greater profits in a tiny profit space, and how carton companies reasonably reduce production costs become the key. The spontaneous activity of "reducing the production cost of corrugated boxes" has been generally carried out. In fact, as long as some subtle links in the production process are solved, the cost of corrugated boxes can be effectively reduced.
Printing
How to keep the color of corrugated cardboard ink printing consistent and accurate layout, thereby reducing the scrap rate, this is a topic of common concern for carton companies. The causes of inconsistent printing colors and "run-out" are mainly due to poor control of ink viscosity; unstable ink transfer state; unstable paper feeding state; poor flatness of cardboard, etc. In order to maintain the consistent color and accurate layout of the corrugated cardboard ink printing, the following points must be achieved:
Keep the ink viscosity stable. Ink viscosity is the main index that needs to be controlled in corrugated cardboard printing. It is one of the main factors that affect the color condition of printing. Due to the volatilization of the ink solvent during printing, its viscosity will increase. In order to maintain the stability of the ink viscosity, the ink stabilizer should be added every 0.5 hours to 1 hour, the amount of addition is 1% to 2%;
Keep the ink transfer volume stable. Because the printing speed is related to the state of ink transfer, it is important to keep the printing speed balanced and stable. It is also necessary to keep the paper balance evenly, and the phenomenon of interleaving paper feeding cannot occur. Only in this way can the stability of ink printing colors play an important role;
Keep the paper feed stable. In addition to the stable running speed of the printing press, the manual paper feed point should be fixed. For the cardboard with poor flatness, it should be properly handled, such as reversing along one side (or both sides) of the horizontal pressing line of the cardboard; feeding by hand. The gap between the paper guides should be the same, which is an important link related to the stable operation of the cardboard and an important method to solve the "running board" phenomenon;
Keep the printing equipment in good condition. What needs to be emphasized is to keep the anilox printing plate clean and clean, which is directly related to the printing effect. Because the anilox roller is related to the ink transfer performance, the printing plate is related to the clarity of the printed text and patterns.
Die cutting
With the continuous enrichment of the carton printing process and the continuous increase in processing speed, the problems exposed by the die cutting process are increasing. Reasonable control of the production of waste products during the die cutting process has become another important link in "reducing the production cost of corrugated boxes".
Solve the die cutting precision is not high or the die cutting indentation position is inaccurate
The position of the die-cutting indentation line does not match the position of the printed product. The reasons for this failure are as follows:
(1) The manufacturing process of the die-cutting knife version has errors, and it cannot absolutely reach the ideal die-cutting indentation position. At present, there are mainly two methods for making die-cutting knife plates: manual plate making and laser plate making. The precision of laser plate making is relatively high. The design and cutting are done by computer and machinery, which is suitable for die cutting of middle and high-grade packaging. The manual plate-making method has high requirements on the platemaker's technical level. The plate-making machine is affected by various factors such as the platemaker's technical level and experience. It is suitable for medium and short-version packaging with low accuracy requirements. Therefore, in order to get good die cutting accuracy, you must choose an advanced plate-making method;
⑵ Cardboard mouths have different rules. All die cutting machines themselves will produce precision errors. To improve the accuracy of die cutting indentation, we must choose a high precision die cutting machine. If the specification error of the cardboard check mouth is large, it may be that the dialing machine's rear positioning (also called secondary positioning) dialing distance is too small, which can be solved by adjusting the rear positioning and increasing the rear positioning dialing distance;
⑶The position of die-cutting indentation and printing is not aligned, the solution is to re-calibrate the die-cutting plate according to the product requirements, and correct the position of the printing and die-cutting indentation. It can also be adjusted by adjusting the positioning rule or front Positioning rules to correct, so that the die-cutting indentation and the printing grid register.
â‘·Different working environment of die cutting and printing will cause deformation or stretching of cardboard fibers, and will also make the die cutting indentation inaccurate. Should try to ensure that the die-cutting indentation to ensure the identity of the working environment (ie, have the same temperature, humidity, etc.).
Solve the "dark line" or "fried line" indentation line is not clear
"Dark line" refers to the indentation line that should not be there; "Explosive line" refers to the excessive pressure of die-cutting indentation, which exceeds the tolerance limit of the cardboard fiber, causing the cardboard fiber to break or partially break. There are several reasons for this failure:
The selection of indentation line and indentation die is inappropriate. The type of indentation line and the height of indentation line can be selected as follows
When die cutting corrugated paper:
The groove depth of the indentation die = the real-time paper thickness of the corrugated paper
The groove width of the indentation die = 2 times the paper thickness of the corrugated paper + the thickness of the indentation line
The height of the indentation line = the height of the die cutter-the real-time paper thickness of the corrugated paper
Improper pressure adjustment of the molding machine. The pressure regulating mechanism of the die cutting machine should be adjusted to properly adjust the pressure of the die cutting machine;
The thickness of the adhesive paper on the fixed pad is not accurate. Because the pad paper is too low or too high, the adjustment method is to re-pad paper;
The paper quality is too poor or the paper moisture content is too low. The increased brittleness of the paper and the decrease in toughness will also result in thread explosion, which can be solved by increasing the ambient temperature.
Solve irregular indentation lines
The reasons for this failure are:
The poor width of the indentation die is uncomfortable. The groove width of the indentation mold can be reselected according to the above method;
The seam on the die-cutting blade is too wide, and the indentation line twists under the pressure of the die-cutting indentation. The solution is to replace the knife plate and use a qualified die-cutting and indenting knife plate
Solve cracks in cardboard creases when folding paste boxes
When folding the paste box, if the outer side of the cardboard indentation line is cracked, it is because the indentation line is too deep or the width of the indentation die is not enough; if the inner side of the cardboard is cracked, it is because the die cutting indentation pressure is too high, and the paper fiber breaks. The solution is to appropriately reduce the pressure of the die-cutting machine, switch to a slightly lower indentation line, or widen the indentation line according to the cardboard thickness.
Solve the problem of die-cut loose version
The loose version caused by die-cutting is mainly related to the plate-making process and the pop-up strip (or sponge). The causes of failure are as follows:
Die-cutting is small and small. If the shape of the live parts is complex or there are many arranged live parts, and the die-cutting connection points are small and few, it is easy to cause loose version during die-cutting. The number of connecting points should be appropriately increased; in addition, the length direction of the printed product should be as consistent as the paper transport direction when making plates;
The strip of stripped paper sticked to the die-cut plate has low hardness. If the sponge is too soft, the paper can not be smoothly separated from the die cutter or the indentation line, so the loose version is caused. It should be replaced with high-quality sponge strips with high hardness and good elasticity.
With the development of packaging and printing technology, product packaging with bright colors, generous design, clear lines, smooth, non-explosive lines, non-explosive colors, lint-free, and no paper dust will be more favored by users.
Warehousing
In the "reduction of corrugated carton production costs" of carton companies, it is also very important for the storage of finished carton to achieve a good moisture-proof effect. In addition to the use of some pulp improvers and additives, other factors should also be noted. In the storage process, how to solve the problem of carton moisture resistance:
Cardboard that has just come off the production line should be blown away in time in the direction of the corrugation to cool and set it;
When stacking corrugated cardboard, it should be stacked on both sides (10 to 20 sheets on each side), the height should be appropriate, and a certain pressure should be applied on the top to make the corrugated cardboard flat and not deformed;
The storage warehouse should be high, the surrounding drainage should be unobstructed, and the ventilation should be good to facilitate air convection;
When stacked in the open or in the open air, it must be covered with plastic film, cushioned with sleepers, and the height from the ground should be greater than 150mm, covered with a tarpaulin to prevent rain water from being wet;
Corrugated cardboard is strictly forbidden to sit, lie or apply heavy objects to prevent collapse.
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