Composite film printing operation standards
1. Production preparation
Before the production of the compound roll film, the captain, co-adjuster, and unwinder carefully read the production instructions and process instructions. It must be clear which order should be produced and the product name, product structure, production quantity (including the number of meters and kilograms) and other requirements of the order.
Ink adjusters should be particularly clear:
1. What are the specific requirements of printing standards or printing standards?
2. Color number and color sequence required by the product
3. Ink grades required by each color
4. Types and ratio of solvents required for each color
5. Viscosity controlled by various colors
In particular, the unwinder and unwinder should be clear:
1. Types, specifications (including thickness and width) and quantity of required substrates
2. Color number and color sequence required by the product
3. Product name and version number
4. Direction of loading
5. The viscosity, temperature and pressure of the pressure roller should be controlled for each color
The captain is especially clear:
1. Perimeter of plate roller
2. Direction of loading
The above requires three people to do it in their first time.
Production order: In general, the production order refers to the "production order table", and in special cases (such as emergency insertion of orders) refers to the verbal instruction of the printing supervisor or production manager. Pay special attention not to accept instructions from any other person.
The production team must produce in strict accordance with the order stipulated in the production instructions, and no changes are allowed. When the scheduled order does not meet the production conditions, it should be reported to the corresponding supervisor. After approval, the order can be skipped and subsequent orders can be produced in sequence.
Process instruction: In general, the process instruction refers to the "printing process card", in special cases it refers to the temporary written notice of the printing supervisor or the manager of the production department (the written notice must have the signature and specific date of the corresponding person). Accept unwritten notices and instructions from other personnel.
Second, confirm the production conditions
The captain confirmed:
1. Whether the printing roller is issued and whether it is consistent with the product to be produced.
2. Check whether the version number corresponds to the correct number of plates. Check whether the plate roller is damaged.
3. Whether the required number of printing units is complete, whether the functions are normal, and whether the required pressing rollers are complete.
Toner confirmation
1. Whether to provide printing standard samples (at the time of turning over production).
2. Have you provided a description of the printing standards, whether the description is clear and feasible, and whether the materials mentioned in the description are complete (when the new version is printed).
3. Whether the required ink is complete and in place.
Rewind and reel confirm:
1. Whether the required materials are in place and the specifications are correct (use a thickness gauge if necessary).
2. Whether the material is sufficient.
3. Whether the required pressure roller is damaged.
The above work will be carried out by three people at the same time, and will be reported to the captain verbally immediately after completion
3. Start-up preparation
1. When the production preparation work is completed and the production conditions are confirmed after verification, the captain orders the start-up preparation work. If the production conditions are not met and the machine is blindly started, the captain and corresponding personnel shall be held responsible.
2. Plate installation: lock the plate roller after positioning the plate shaft accurately
The captain and the unwinding and rolling machine cooperate to install the plate: lift the plate roller to the plate loading car with a blanket, and insert the plate shaft from the correct section of the plate roller according to the direction of the plate installation. The plate roller should be checked again for damage during the plate installation process.
3. Previous version: Put the installed version roller to the corresponding printing unit
The captain and the take-up and roll-off manipulator cooperate with the upper plate: carefully lift the installed plate roller into the corresponding printing unit, and connect the coupling ink.
4. Install and install the plate rollers of other units in sequence
Throughout the process of loading and loading plates, you must cooperate well and carefully, paying special attention to personal safety, and at the same time, be careful not to damage the plate roller.
5. Inking: Add the required ink to the corresponding ink tank
The inking work is carried out by the ink adjuster while the co-workers install the plate: the ink adjuster sequentially adds the required ink to the corresponding ink tank according to the requirements of the "printing process card", and at the same time starts the ink pump to make the ink circulation smooth.
note:
â‘ Use old ink as much as possible, but the amount of used ink should not exceed a quarter of the ink volume.
â‘¡ The ink in the ink tank should be sufficient, but the primary color ink in the ink tank should not exceed two thirds of the capacity (so that the solvent is added when adjusting the viscosity), and the spot color ink should not exceed one half of the capacity. (In order to add ink and solvent when adjusting ink)
â‘¢ Spot color ink should be loaded at the end.
â‘£ Make sure that the final (during normal production) ink level is not less than 125px from the top edge of the barrel .
6. Ink adjustment : adjust the hue of each color ink
The ink adjustment is done by the ink adjuster:
â‘ The color ink does not need to be adjusted before adding the proofing ink. After the first proofing, the appropriate amount of adjustment ink should be added according to the effect. Note: Adding too much ink will reduce the texture effect of the gradation part, make the gradation part dull, the contrast between light and dark is not strong, and the tone is dull and not bright.
â‘¡When adjusting the spot color ink, you should first scrape the sample with an ink stick, or use other methods to compare the colors. The ink should be stirred quickly to make it evenly mixed, and the hue should be as close as possible to the requirements of the sample. Proofing work is strictly prohibited if the hue effect is very different.
â‘¢When adjusting the spot color ink, the ink adjuster should pay attention to the ink mixing ratio and record it on the "printing process card" during normal production. The ink adjuster without the concept of ink mixing ratio is not a qualified ink adjuster.
7. Adjust the viscosity: that is, add an appropriate amount of solvent to the ink to make the ink meet the process requirements.
â‘ Adjustment of viscosity is done by ink adjuster:
â‘¡It is more appropriate to adjust the viscosity after finishing the inking work.
In general, color ink and black ink use color ink solvent to adjust viscosity, and white ink and spot color ink use white ink solvent to adjust viscosity.
When the screen formation is lighter (according to proofing or printing standard samples), a solvent that dries more slowly than the color ink solvent should be used.
When the white version or spot color version becomes lighter due to wear, the color ink solvent should be used.
â‘¢ Proofing work without adjusting the viscosity is strictly prohibited.
8. Install the pressure roller: put the pressure roller of suitable specifications and hardness on the roller shaft
The captain and the take-up and unwinding cooperating to install the pressure roller, lift the pressure roller to the plate loading vehicle equipped with felt, and penetrate the roller shaft. During the installation of the pressure roller, the pressure roller should be checked again for injuries.
9. Upper pressure roller: put the installed pressure roller to the corresponding printing unit
The captain and the take-up and roll-off manipulator cooperate with the press roller: carefully wipe the installed press roller carefully, carefully lift into the corresponding printing unit, and lock it.
10. Install and press the rollers of other units in sequence.
During the entire process of installing the pressure roller and the upper pressure roller, it must be well coordinated and carried out carefully, paying special attention to personal safety and at the same time not to damage the pressure roller.
11. Upper scraper
Under normal circumstances, the ink adjuster applies the ink and adjusts the ink before the upper plate and the upper pressure roller. At this time, the ink adjuster should perform the work of the upper blade. That is, according to the characteristics of the net, adopt a hard or soft way to install the scraper straight into the scraper holder. At the same time, the ink on the blade holder near the blade should be cleaned.
Note: When installing the squeegee, pay special attention to the printing distance (the distance between the squeegee edge and the embossing point), the squeegee angle, and the parallelism between the squeegee edge and the plate axis. A problem has a great influence on the degree of hue balance.
12. Put the scrapers of other printing units in turn
13. Grinding scraper
Both new and old scrapers should be polished with 800- mesh metallographic sandpaper and machine oil. The sandpaper should be stacked in several layers to avoid injury to the hands. The wrist should be perpendicular to the blade surface when grinding, and the fingers must be lifted up and not dragged on the blade surface To avoid cutting your fingers.
14. Wiper blade
Carefully wipe off the scraper with a rag soaked in solvent (including oil and residual ink under the scraper).
Note: After each shutdown, wipe the blade again before restarting.
15. Loading
Immediately after loading the plate and pressing the roller, the unwinder and unwinder will start feeding (this work can also be done at the beginning)
â‘ Load scraps of suitable specifications into the unwinding shaft
â‘¡Check the corona treatment surface of the product material, and put the material with the processing value into another unwinding shaft
â‘¢Select a paper tube of appropriate length, pass through the winding shaft, lock up to the material rack, and wrap the tape
â‘£Select a paper tube of appropriate length, insert it into another winding shaft, lock up to the material rack, and wrap the tape
note:
â‘ The materials used in the product must be checked inside the corona and the processing value. Only materials with the processing value that meets the standard can be used on the machine.
â‘¡ Make sure that the corona treated surface is used for the printed surface.
16. During the start-up preparation process, it is not allowed to open the oven temperature and start the burner, so as to avoid unnecessary power loss.
Four, boot
1. Starting conditions
The start-up work can only be carried out after the start-up preparation work is completed.
2. Power on
The captain turned on the main motor to make the plate roller run at low speed, and started the burner, oven temperature and fan at the same time.
3. Tape wrapped
Ink adjusters and retractors use tape to wrap the plate roller plugs and plate shaft thread parts to avoid the ink sticking to it during operation and affecting the next plate installation.
4. Open the ink tank
The three acted separately, raising the ink tank and immersing the plate roller in the ink tank 3-100px .
5. Adjust the scraper
The three acted separately, lowered the squeegee to touch the layout, adjusted the printing distance initially according to the characteristics of the web, and adjusted the squeegee to be balanced, so that the squeegee was basically good. Then press the start switch, if the squeegee effect is still not good, The feed distance at both ends of the scraper should be adjusted evenly until the scraping is good.
Note: When the scraping ink is not clean, the starting pressure of the scraper should be appropriately increased, and mechanical pressure is not allowed to avoid shortening the service life of the scraper or the life of the plate roller.
6. Set process parameters
The captain's black dicing unwinding tension, winding tension, unwinding tension, unwinding tension and front and rear traction roller pressure.
7. Dropping roller
The ink adjuster and retractor roll start from the first color and press the printing roller once to control the pressure within the specified range.
8. Preliminary Overprint
The three people perform the operation simultaneously, and operate separately. The manual and horizontal overprinting are performed in two directions. After the accuracy is basically accurate, switch to the automatic mode.
9. Coarse ink adjustment
When the ink color is displayed, the ink adjuster must immediately carry out the color matching work without having to wait for the overprint to stop completely and accurately before adjusting the ink. When the ink color difference is far away, the film is still running in time, and it can also be used for rough color matching (either spot color or gradation effect). At this time, the ink should be adjusted as soon as possible, and the film can be cut and sampled for color comparison when the machine is running. Only after the newly adjusted ink color comes out and the hue is basically close, can you stop the color matching when the overprint is basically accurate. Before coarse adjustment of the ink, the required ink must be prevented in advance to the place where it is available, and the phenomenon of finding ink everywhere when ink is needed should be avoided.
10. Color matching
â‘ After the overprint is basically accurate, the captain stops and the ink adjuster compares the colors. The color matching should be carried out only after the adjusted ink is mixed evenly.
â‘¡According to the requirements of printing standards or printing standards, detailed color comparison should be carried out on the hue of each color block of the entire pattern at once, and it is not allowed to compare the hue of only some of the color blocks at one time.
â‘¢When comparing colors, the corresponding materials (such as pearlescent film, aluminized film, white paper board, etc.) should be paved under the substrate according to the requirements of the product structure.
11. Fine-tune ink
â‘ The ink adjuster carefully adjusts the ink according to the color comparison result, and mixes the ink as soon as possible.
â‘¡ At this time, the captain should adjust the balance bar according to the overprint effect.
â‘¢ The task of the ink adjuster is to complete the ink adjustment work at the same time as the captain completes the color registration.
12. Initial inspection
â‘ While the ink adjuster is comparing the color and toning, the captain should carry out the initial inspection to check whether the product has defects other than hue, such as: wrong printing of the product, poor transfer of shallow screen, plugging, knife wire, and ink scraping. Net, ink hair color, indentation, etc.
â‘¡ While the ink adjuster is comparing colors and toning, the captain will deal with it as soon as possible according to the structure of the initial inspection, and should ensure that any problems that occur before proofing are resolved.
â‘¢While the ink adjuster is grading, the rewinding and rewinding worker performs auxiliary grading and color registration.
13. Proofing
â‘ After fine-tuning the ink, start proofing.
â‘¡If the hue fails to meet the standard, the color comparison and color adjustment process must be repeated.
V. Signing
Regardless of the production of new orders or reversal of orders, production can only be carried out after the sample is signed, and production cannot be carried out without completing the signing.
When printing for the first time:
â‘ Customer signing: After the customer signs the sample, the printing team adopts the sample film directly connected to the sample film, the captain indicates the words "customer signing", and signs the captain's name and date as the printing standard kind. Note: For every proof during the printing process, the sample should be retained, and the number of proofs should be marked with a signature pen, and the customer's improvement requirements should be marked in the corresponding position on the sample. Until the customer is satisfied. After the customer approves the signature, some of the samples can be used as the deviation limit as required.
â‘¡Internal sample signing: In the case of production needs or the production team is difficult to grasp the printing standard, the person in charge of plate making or printing supervisor or the manager of the production department or the marketing department can be responsible for signing the sample. Sample date.
â‘¢Sample signing of the team: If there is no special signing requirement, the captain of the production team will sign the sample according to the printing standards or the requirements of the printing samples.
When turning orders:
â‘ When the printing volume is too large, and the printing effect is difficult to meet the requirements of standard samples, the production team shall not produce without authorization, and shall report to the printing supervisor or the manager of the production department to re-determine and sign the printing standard samples.
â‘¡Even if it is to turn over production, it must be signed by the captain when starting the machine, and each captain must also sign the sample again after analyzing the work sign when he takes over.
6. Formal production
1. Requirements for formal production
After the overall hue meets the requirements, formal production can be carried out at the same time as the sample is signed. At this time, it should be ensured that the overprint is accurate and all the waste products are discharged.
2. First inspection
The first inspection should be carried out by the captain at the same time as the official production, and the nearest part of the sample film (which has been cut off) before the official production will be fully inspected.
( 1 ) Poor ink adhesion
( 2 ) Is the product printed wrong?
( 3 ) Hue deviation
( 4 ) Plug version (block version)
( 5 ) With wire (knife wire)
( 6 ) With ink (foggy version, overflowing ink, scraping ink is not clean)
( 7 ) Missing print (the pressure roller can not be pressed)
( 8 ) Indentation
( 9 ) Flying ink
( 10 ) Odor
( 11 ) Ink color hair
( 12 ) Overprint deviation
( 13 ) Anti-stick
( 14 ) Re-dissolve (poor color registration, tailing, etc.)
( 15 ) The size deviation is too large (stretch or shrink)
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