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The reduction of label printing waste rate will enhance the core competition of printing enterprises

Source:Dongguan Deli Intelligent Technology Co., Ltd.      Time:2021-04-25 17:48:36

In recent years, the environment of the printing industry has become more and more severe. On the one hand, it has been affected by the adjustment of domestic macroeconomic structure and models. The downturn of the real economy has caused fluctuations in the demand for the printing industry; on the other hand, the market has kept improving the quality of printing. Therefore, traditional printing companies will inevitably lead to an increase in operating costs if they want to achieve a high-quality printing model; finally, the promotion of environmental protection policies and the sharp increase in paper prices have put forward new requirements for the quality process control of printing companies.


As an important part of printing intelligent manufacturing, visual quality inspection system determines the development speed and automation level of printing intelligent manufacturing. In the traditional printing mode, due to low labor costs, controllable raw material prices, and no environmental protection pressure, printing companies tend to ignore the production quality cost, and use automatic quality inspection equipment mainly for quality inspection before leaving the factory. As long as the products delivered to customers are not large The quality problem is fine. Nowadays, the environment of the printing industry has undergone earth-shaking changes, with high labor costs, rising prices of raw materials, strict environmental protection requirements, and increasing customer quality requirements. Therefore, in pre-press and printing, it is particularly important to improve the quality process control of printing enterprises, reduce printing costs, and promote the development of intelligent manufacturing in the industry through intelligent detection technology through the production process from the source. This is why most printing enterprises are increasingly The more urgent the need.


Quality control status and existing problems


In the entire printing process chain, the total product yield is generally 90% to 95%, and printing companies need to bear 5% to 10% of the waste rate loss every year. In the past few years, domestic printing companies focused on how to sort good and bad products to improve the rate of finished products delivered by customers. Regarding the current situation, how to reduce the rejection rate of 5% to 10% will be the leading direction for enhancing the core competitiveness of printing enterprises.


The frequency of quality problems in various process links of a number of printing companies has been investigated. After data analysis, it is found that the proportion of quality problems in each process link is different. The proportion of quality problems in pre-press document design and plate making is about 10%, especially in gravure and flexo plate making, and the book printing industry is no exception. The quality problems in the printing process account for the largest proportion in the entire process chain, about 45%. The proportion of printing color difference is about 30%. Generally speaking, the quality problems caused by post-press processing account for at least about 10%. From the perspective of the entire data distribution, to reduce the quality problems of the entire printing production process and increase the yield rate, the focus of quality control should be focused on prepress and during printing, saving materials and labor, and replacing final product inspection with process inspection. Enterprises reduce costs.


Pre-press quality control


To control the quality of pre-press, we need to grasp two 100% core elements.


The completion of a printed matter mainly includes pre-typesetting design, proofing, finalization, plate making, printing, post-processing, quality inspection, and packing out. Pre-press production is the beginning of the entire printing process, it is an important link in printing quality control, and printing is a means of semi-finished product completion and mass reproduction. If the pre-press design staff understand the characteristics and requirements of printing, they can more effectively convey the design and production concept to achieve the best printing effect.


Conversely, if the pre-press designers have insufficient knowledge of the printing characteristics, it will be technically difficult to realize the design draft when it is delivered for printing, or even cannot be printed, which will cause an unnecessary increase in printing costs. Therefore, pre-press production staff need to understand the various printing processes, and be proficient in using various types of typesetting and imposition software, and can accurately and effectively perform pre-press processing. When there are problems in the follow-up process, they can also find the pain points and solve them in time, thereby effectively reducing printing. Cost of production.


1. Ensure 100% accuracy of the first printed sample


Start inspection and supervision from the printing plate before printing, and use the original standard electronic documents provided by the customer and the large-format electronic documents to establish templates to detect the first proof of printing to avoid printing plate defects, printing plate errors or The surface of the blanket is not clean, causing the entire batch of printed matter to be scrapped. In the mass printing process, use single-page product sample sheets and large-page product sample sheets to create templates, inspect and supervise the printing quality and printing accuracy of the printed matter at different levels, use objective data to guide manual operations, eliminate artificial instability factors and avoid employees Human error caused by visual fatigue improves the efficiency and accuracy of printing quality inspection, greatly saves printing costs, uses real data to guide production and objective data to control production.


At the same time, in the color mixing process before printing, the color difference of the full width of the sample is quantitatively measured by scanning and sampling the print sample, guiding the printer to accurately follow the color, reducing the amount of paper used, and improving production efficiency.


2. To ensure 100% accuracy of printed manuscript design and editing


The printing company first needs to edit and modify the standard printed document (standard electronic document) provided by the customer, and finally, after the customer confirms, sign and agree to impose the large version of the electronic document according to this document, and finally RIP raster on the basis of the final draft. Process, and finally make a printing plate. In the above workflow, publishing defects may appear in the imposition process, because the process of assembling the confirmed small version of the document into the large version of the electronic document is likely to cause the lack of information or graphics.


In addition, there are many printed pictures and texts, especially special foreign orders involving foreign languages. Manual verification can no longer completely eliminate publication errors. In order to reduce unnecessary waste, it is imperative to use detection software to assist manual methods to detect all errors in the electronic file production process. The detection software compares the standard file provided by the customer with the edited file to prevent editing errors; compares the compared edited file with the imposition large-format file, and eliminates imposition errors in time; The large version of the electronic file that has been used is compared with the plate-making file to effectively ensure the accuracy of the plate-making file. Our company has launched a testing software specifically for the version matching process.


India-China Quality Control


The best method for quality control in India and China is online testing.


Printing is a dynamic process, and many factors affect the quality of the printing process. The influencing factors of raw materials, such as the durability of the printing plate, the characteristics of ink and paper; the influencing factors of the printing machine, such as water and ink balance, printing pressure, paper stability, etc.; the influencing factors of the printing environment, such as temperature and humidity; man-made Influencing factors, such as the captain’s operating level and the level of quality awareness.


Install the printing quality online inspection system directly on the printing press to perform real-time online inspection of the printing quality, which can effectively reduce the quality risks caused by various printing factors. At the same time, production management, quality management, equipment management, etc. can be realized based on accurate quality data. Analyze the status of each machine and equipment through quality information statistics, so as to predict, find, and diagnose faults, ensure the effective operation of equipment, and improve production efficiency and product quality. The online inspection system can also make online statistics on the consumption of different printing consumables and the output of different printed materials, so that it can be compared with the situation in previous years, so as to balance the consumption of each printing consumable and the business volume of each print in the later production.


The quality problems arising from the pre-press and intermediate stages are the "big tigers" that printing companies urgently need to crack down. The use of inspection software to control the quality of the pre-press and intermediate stages will surely effectively improve the core competitiveness of printing companies and promote Great development of intelligent manufacturing in the industry.



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