1 Background
Energy conservation and emission reduction is an eternal theme of a national sustainable development strategy. In recent years, with the rise of the environmental protection printing trend, printing technologies for energy saving and emission reduction have attracted more and more attention and attention from the industry. In these technologies, the roll production process of roll-to-roll is used to save the cost of paper. With special attention, according to statistics, the roll-to-roll production method does not have a bite edge and drag edge, so it can save more than 2% paper cost compared to sheet-fed production methods. The most important cost of paper packaging, especially cigarette printing, is a considerable cost.
However, since the roll-to-roll production method of web was born for many years, it has not been the mainstream production method for cigarette pack printing. This has a direct relationship with the relatively late post-press processing technology, especially the hot stamping technology. For a long time in the past, the products of cigarette reel packaging were mostly low-grade cigarettes. The printing process of these cigarette packets was relatively simple and basically belonged to pure printing products, but with the popularization of bronzing technology, some cigarette packs used reel packaging In order to improve the packaging quality, it has also begun to increase the renovation requirements of the bronzing process. Because of this demand, several forward-thinking equipment developers at home and abroad have begun to develop matching hot stamping units on cigarette pack printing machines and succeeded, but this is only limited to simple flat ironing. However, the packaging of mid- to high-end cigarette brands, which are mainstream products, has a process of embossing and holographic positioning of bronzing. Even both of them have both, and at the same time, both the hot and holographic positioning of the roll-to-roll production process and the online The question of quality inspection will be a major problem faced by printing equipment factories and printing factories. Below we will conduct some preliminary research and discussion on the solution of these problems from the aspects of equipment, plate making, quality inspection, and process routes.
2 hot stamping equipment
At present, domestic and foreign companies that can develop professional cigarette packs for roll-to-roll bronzing equipment are mainly Swiss Bosite, Swiss Gushi, Tianjin Changrong, and Wuhan Jincai. Among these companies, Switzerland BOBST and Wuhan Jincai Co., Ltd. in China can develop roll-to-roll round presses, while Swiss Gushi and domestic Tianjin Changrong can develop roll-to-roll flat presses. Hot foil stamping machine can basically achieve roll-to-roll convex hot + holographic positioning hot. For different product structures, round-to-round and flattened roll-to-roll stamping machines have their own advantages. The hot-rolling method for roll-to-roll round-to-round is a line contact method for hot stamping. The hot stamping speed is high and the production efficiency is high. Larger hot, fine lines, and holographic positioning; hot-to-roll flat and flattened hot stamping is a hot stamping method with surface contact. The hot stamping speed and production efficiency are lower than those of round press circles, but the adaptability to convex hot and There are advantages in hot stamping, and its plate making cost is also relatively low. Due to historical reasons, most of the hot stamping products of existing cigarette packs are completed on a single flattening hot stamping machine, and are flat and flat. Convex scalding and round embossing are slightly different in effect. Therefore, for products that have the following requirements, customers will often consider using flat-to-roll flat-flushing hot stamping machines.
3 Plate material
For the production of hot stamping, if the original hot stamping method is changed from a round press sheet paper bronzing to a round press roll-to-roll bronzing, or from a flat-press sheet paper gilding to a flat press roll Roll bronzing, you can follow the original production version. If the original hot stamping method is changed from a circular press sheet-fed hot stamping to a flat-flattened roll-to-roll stamping or a flat-pressed sheet-fed hot stamping to a round-pressed roll-to-roll hot stamping, according to the product The convex hot effect adjusts the plate making process to make it as close as possible to proofs. With regard to the current domestic and international platemaking technologies, there is no great difficulty in such a change.
In the case of anodized aluminum, if the original hot stamping method does not change in terms of roundness and flattening, the anodized aluminum can be used to produce anodized aluminum. If the original hot stamping method is changed from round pressing to flat pressing or vice versa, then the aluminum type plastic formula needs to be adjusted. It can be basically solved by a few times of testing by relevant aluminum manufacturers.
4 Quality inspection
One of the most important steps in roll-to-roll embossing and holographic positioning is the quality inspection. The biggest weakness of the roll-to-roll inspection is that it cannot sample the product online. This is also one of the important reasons behind the application of roll-to-roll bronzing technology in the application of sheet-foil bronzing technology. Therefore, to fully realize the roll-to-roll convex hot + holographic positioning hot production, the first problem is to solve the problem of online quality inspection. However, in the detection process, the change of the rainbow effect of holograms in holographic aluminum is not a small test for on-line detection, and it is also a difficult task to overcome for a period of time, especially the convex hot and holographic positioning of different aluminum foils. It is even more difficult for hotspots to test their quality at the same time online. At present, there are three companies at home and abroad claiming that they have developed a quality inspection system that can detect holograms. They are the Israeli AVT quality inspection system, the German E+L quality inspection system and Beijing Lingyun's quality inspection system. All three quality inspection systems can be installed on roll-to-roll bronzing equipment for simultaneous online inspection, and can record, alarm, and display quality problems that occur during the bronzing process. They can also determine their location through the roll-back system and use replacements. The method completes the production of the finished reel. Among the three quality inspection systems, the Israel AVT quality inspection system and the German E+L quality inspection system use the system quality inspection method. The Beijing Lingyun quality inspection system adopts the dual system quality inspection method. From the experimental results, the dual-system quality inspection method is more effective in detecting various fine flaws in hologram bronzing. Therefore, when selecting a roll-to-roll convex bronzing + holographic positioning gilding quality inspection system, it is recommended to select double System quality inspection method.
5 Route Selection
For the more difficult holographic positioning hot stamping reel products in the current fine cigarette packs, we recommend the best process route: multi-color gravure + still image quality inspection → offline holographic positioning hot + convex hot duplex Hot stamping + dual system quality inspection → offline rewinding and rewinding → single volume secondary quality inspection → rewinding stitching → finished product storage.
6 Thinking about problems
1) If round press double press hot stamping is used, the effect on the convex hot part will be less than that of the original flat press. If the flattening double station hot stamping is used, the registration of the holographic positioning hot will have some problems when the layout is large, and it is a problem for such a reeling product. Of course, here is an idea that can be achieved in a set of equipment, a station for the round pressure round, while the other station is flattened to solve the above problem, which requires bronzing equipment manufacturers to further study the test.
2) Production process
1 After the soft paper is hot, after a large tension, the convex hot effect will have a certain influence, and will be slightly different from the original.
2 Asymmetric convex hot, whether it will affect the normal packaging production of the cigarette factory wrapping machine due to the size of the reel.
Above, we mainly carried out preliminary research and discussion on the basis of related experiments on the roll-to-roll holographic positioning hot stamping hot stamping cigarette production process. There may be many problems in the future batch production that need to be solved continuously. If a new gilding new process can be realized in batches in production, it will have better results for improving production efficiency, saving raw materials and promoting energy conservation and emission reduction.
Energy conservation and emission reduction is an eternal theme of a national sustainable development strategy. In recent years, with the rise of the environmental protection printing trend, printing technologies for energy saving and emission reduction have attracted more and more attention and attention from the industry. In these technologies, the roll production process of roll-to-roll is used to save the cost of paper. With special attention, according to statistics, the roll-to-roll production method does not have a bite edge and drag edge, so it can save more than 2% paper cost compared to sheet-fed production methods. The most important cost of paper packaging, especially cigarette printing, is a considerable cost.
However, since the roll-to-roll production method of web was born for many years, it has not been the mainstream production method for cigarette pack printing. This has a direct relationship with the relatively late post-press processing technology, especially the hot stamping technology. For a long time in the past, the products of cigarette reel packaging were mostly low-grade cigarettes. The printing process of these cigarette packets was relatively simple and basically belonged to pure printing products, but with the popularization of bronzing technology, some cigarette packs used reel packaging In order to improve the packaging quality, it has also begun to increase the renovation requirements of the bronzing process. Because of this demand, several forward-thinking equipment developers at home and abroad have begun to develop matching hot stamping units on cigarette pack printing machines and succeeded, but this is only limited to simple flat ironing. However, the packaging of mid- to high-end cigarette brands, which are mainstream products, has a process of embossing and holographic positioning of bronzing. Even both of them have both, and at the same time, both the hot and holographic positioning of the roll-to-roll production process and the online The question of quality inspection will be a major problem faced by printing equipment factories and printing factories. Below we will conduct some preliminary research and discussion on the solution of these problems from the aspects of equipment, plate making, quality inspection, and process routes.
2 hot stamping equipment
At present, domestic and foreign companies that can develop professional cigarette packs for roll-to-roll bronzing equipment are mainly Swiss Bosite, Swiss Gushi, Tianjin Changrong, and Wuhan Jincai. Among these companies, Switzerland BOBST and Wuhan Jincai Co., Ltd. in China can develop roll-to-roll round presses, while Swiss Gushi and domestic Tianjin Changrong can develop roll-to-roll flat presses. Hot foil stamping machine can basically achieve roll-to-roll convex hot + holographic positioning hot. For different product structures, round-to-round and flattened roll-to-roll stamping machines have their own advantages. The hot-rolling method for roll-to-roll round-to-round is a line contact method for hot stamping. The hot stamping speed is high and the production efficiency is high. Larger hot, fine lines, and holographic positioning; hot-to-roll flat and flattened hot stamping is a hot stamping method with surface contact. The hot stamping speed and production efficiency are lower than those of round press circles, but the adaptability to convex hot and There are advantages in hot stamping, and its plate making cost is also relatively low. Due to historical reasons, most of the hot stamping products of existing cigarette packs are completed on a single flattening hot stamping machine, and are flat and flat. Convex scalding and round embossing are slightly different in effect. Therefore, for products that have the following requirements, customers will often consider using flat-to-roll flat-flushing hot stamping machines.
3 Plate material
For the production of hot stamping, if the original hot stamping method is changed from a round press sheet paper bronzing to a round press roll-to-roll bronzing, or from a flat-press sheet paper gilding to a flat press roll Roll bronzing, you can follow the original production version. If the original hot stamping method is changed from a circular press sheet-fed hot stamping to a flat-flattened roll-to-roll stamping or a flat-pressed sheet-fed hot stamping to a round-pressed roll-to-roll hot stamping, according to the product The convex hot effect adjusts the plate making process to make it as close as possible to proofs. With regard to the current domestic and international platemaking technologies, there is no great difficulty in such a change.
In the case of anodized aluminum, if the original hot stamping method does not change in terms of roundness and flattening, the anodized aluminum can be used to produce anodized aluminum. If the original hot stamping method is changed from round pressing to flat pressing or vice versa, then the aluminum type plastic formula needs to be adjusted. It can be basically solved by a few times of testing by relevant aluminum manufacturers.
4 Quality inspection
One of the most important steps in roll-to-roll embossing and holographic positioning is the quality inspection. The biggest weakness of the roll-to-roll inspection is that it cannot sample the product online. This is also one of the important reasons behind the application of roll-to-roll bronzing technology in the application of sheet-foil bronzing technology. Therefore, to fully realize the roll-to-roll convex hot + holographic positioning hot production, the first problem is to solve the problem of online quality inspection. However, in the detection process, the change of the rainbow effect of holograms in holographic aluminum is not a small test for on-line detection, and it is also a difficult task to overcome for a period of time, especially the convex hot and holographic positioning of different aluminum foils. It is even more difficult for hotspots to test their quality at the same time online. At present, there are three companies at home and abroad claiming that they have developed a quality inspection system that can detect holograms. They are the Israeli AVT quality inspection system, the German E+L quality inspection system and Beijing Lingyun's quality inspection system. All three quality inspection systems can be installed on roll-to-roll bronzing equipment for simultaneous online inspection, and can record, alarm, and display quality problems that occur during the bronzing process. They can also determine their location through the roll-back system and use replacements. The method completes the production of the finished reel. Among the three quality inspection systems, the Israel AVT quality inspection system and the German E+L quality inspection system use the system quality inspection method. The Beijing Lingyun quality inspection system adopts the dual system quality inspection method. From the experimental results, the dual-system quality inspection method is more effective in detecting various fine flaws in hologram bronzing. Therefore, when selecting a roll-to-roll convex bronzing + holographic positioning gilding quality inspection system, it is recommended to select double System quality inspection method.
5 Route Selection
For the more difficult holographic positioning hot stamping reel products in the current fine cigarette packs, we recommend the best process route: multi-color gravure + still image quality inspection → offline holographic positioning hot + convex hot duplex Hot stamping + dual system quality inspection → offline rewinding and rewinding → single volume secondary quality inspection → rewinding stitching → finished product storage.
6 Thinking about problems
1) If round press double press hot stamping is used, the effect on the convex hot part will be less than that of the original flat press. If the flattening double station hot stamping is used, the registration of the holographic positioning hot will have some problems when the layout is large, and it is a problem for such a reeling product. Of course, here is an idea that can be achieved in a set of equipment, a station for the round pressure round, while the other station is flattened to solve the above problem, which requires bronzing equipment manufacturers to further study the test.
2) Production process
1 After the soft paper is hot, after a large tension, the convex hot effect will have a certain influence, and will be slightly different from the original.
2 Asymmetric convex hot, whether it will affect the normal packaging production of the cigarette factory wrapping machine due to the size of the reel.
Above, we mainly carried out preliminary research and discussion on the basis of related experiments on the roll-to-roll holographic positioning hot stamping hot stamping cigarette production process. There may be many problems in the future batch production that need to be solved continuously. If a new gilding new process can be realized in batches in production, it will have better results for improving production efficiency, saving raw materials and promoting energy conservation and emission reduction.
Wenzhou Vigorous Pet Products Co.,Ltd , https://www.vigorouspet.com