1 Background
Energy saving and emission reduction is the eternal theme of a national sustainable development strategy. In recent years, with the rise of environmentally friendly printing trends, energy-saving and emission-reducing printing technologies have attracted more and more attention and attention in the industry. In these technologies, the roll-to-roll printing production process can save greater paper costs Special attention is paid. According to statistics, the roll-to-roll production method can save more than 2% of the paper cost compared to the single-sheet production method because there is no bite edge and trailing edge. The most important cost of paper packaging, especially for cigarette pack printing, is a considerable cost.
However, the roll-to-roll production method of web paper has been born for so many years, and it has not become the mainstream production method of cigarette pack printing. This has a direct relationship with the relatively lagging post-press processing technology, especially hot stamping technology. For a long time in the past, most of the products packaged in cigarette packs and reels are low-grade cigarettes. The printing process of these cigarette packs is relatively simple, and they are basically purely printed products. However, with the popularization of bronzing technology, some cigarette packs that use reel packs In order to improve the packaging level, there is also a requirement to increase the bronzing process. As a result of this demand, several visionary equipment developers at home and abroad began to develop and succeed in supporting wire bronzing units on printing machines for commonly used cigarette packs, but this was also limited to simple flat ironing. However, as the mainstream products, most of the packaging of high-end cigarette brands have convex hot stamping and holographic positioning hot stamping processes, or even both, and this production process and online production of convex hot stamping and holographic positioning hot roll to roll products The problem of quality inspection will be a big problem for printing equipment factories and printing factories. Next, 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 Bronzing equipment
At present, the manufacturers that can develop professional roll-to-roll bronzing equipment for cigarette pack production at home and abroad mainly include Swiss Bost Company, Swiss Ji Shi Company, Tianjin Evergreen Company, and Wuhan Jincai Company. Among these companies, Switzerland BOBST and the domestic Wuhan Jincai Company can develop a roll-to-roll round-pressing and hot-stamping machine, while Swiss Ji Shi Company and the domestic Tianjin Evergreen Company can develop a roll-to-roll flat-pressing and hot-stamping machine. The bronzing machine can basically realize roll-to-roll convex hot pressing + holographic positioning hot pressing. According to different product structures, the round-to-round and flat-rolled roll-to-roll hot stamping machine has its own advantages. The roll-to-roll round and round hot stamping method is line contact hot stamping. The hot stamping speed is fast, the production efficiency is high, and the area is particularly suitable Larger flat ironing, fine line hot stamping and holographic positioning hot stamping; roll-to-roll flat stamping is a face-contact stamping method. The stamping speed and production efficiency are lower than those of round stamping. However, the hot stamping adaptability and The hot stamping effect has advantages, and its plate making cost is relatively low. Due to historical reasons, most of the convex hot stamping processing of the existing cigarette pack products is completed on a single sheet flattening hot stamping machine, and the flattening flat Convex scalding and round embossing are slightly different in effect. Therefore, for products that require sample tracking, customers often consider the use of roll-to-roll flat-press flat stamping machines.
3 Plate aspect
For the production of hot stamping, if the original hot stamping method is changed from round flat round sheet paper hot stamping to round flat round roll to roll hot stamping, or flat flat sheet paper hot stamping to flat flat roll to For hot stamping, the original production version can be used. If the original hot stamping method is changed from round flat round paper sheet bronzing to flat flat roll to roll hot stamping or from flat flat sheet paper bronzing to round flat round roll to roll bronzing, then the The convex ironing effect adjusts the plate-making process to make it as close to the proof as possible. With regard to current plate-making technology at home and abroad, such a change does not present much difficulty.
For anodized aluminum, if the original hot stamping method does not change in the round pressing and flattening, then the anodized aluminum can continue to use the original production of anodized aluminum. If the original hot stamping method is changed from round pressing to flat pressing or vice versa, the glue type formula of anodized aluminum needs to be adjusted. It can basically be solved by the relevant anodized aluminum manufacturers with several tests.
4 Quality inspection
One of the most important links in the roll-to-roll convex hot stamping + holographic positioning hot stamping production process is quality inspection. The roll-to-roll quality inspection is better than the single-sheet paper quality inspection. Its biggest weakness is that it cannot sample the products in the online process. This is also one of the important reasons why the application of roll-to-roll bronzing technology lags behind the application of sheet-foil bronzing technology. Therefore, to fully realize the production of roll-to-roll convex hot stamping + holographic positioning hot stamping, the first problem is to solve the problem of online quality inspection. However, during the detection process, the change of the rainbow effect of the hologram in the holographic anodized aluminum is a big test for online detection, and it is also a problem that is difficult to overcome for a period of time, especially the bumping and holographic positioning of different anodized aluminum If it is necessary to check its quality and effect online at the same time, it is more difficult. At present, three companies at home and abroad claim to 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 the Beijing Lingyun quality inspection system. These three quality inspection systems can be installed on the roll-to-roll bronzing equipment for simultaneous online detection, and can all record, alarm and display the quality problems that occur during the bronzing process. They can also be determined by the rewind system and use replacement To complete the production of finished reels. Among the three quality inspection systems, the Israeli AVT quality inspection system and the German E + L quality inspection system adopt the system quality inspection method, and the Beijing Lingyun quality inspection system adopts the dual system quality inspection method. From the experimental results, the dual-system quality inspection method is better at detecting various minor defects in the hologram bronzing. Therefore, it is recommended to choose dual when selecting the quality inspection system for roll-to-roll convex hot stamping + holographic positioning bronzing The quality inspection method of the system.
5 Selection of technological route
For the reel products with holographic positioning and convex hotness, which are more difficult in the current high-quality cigarette packs, we recommend the best process route: multi-color gravure printing + still picture quality inspection → offline holographic positioning hot pressing + convex hot duplexing Bronzing + dual system quality inspection → offline slitting and rewinding → single roll secondary quality inspection → rewinding splicing → finished product storage.
6 Thinking about existing problems
1) If you choose the round pressing round double station hot stamping, the effect on the convex hot part will be worse than the original flat pressing effect. If you choose flat-press double-station hot stamping, the holographic positioning hot register will have some problems when the layout is large, and it is a problem for such reel products. Of course, here is a suggestion, whether one station can be rounded in a set of equipment, and the other station is flattened to solve the above problems, which requires further research and testing by the gilding equipment manufacturer.
2) Production process
â‘ After the soft paper is scalded and rewinded under high tension, the scalding effect will be affected to some extent, and it will be slightly different from the original.
â‘¡Whether the asymmetric convex hot will affect the normal packaging production of the cigarette factory roll wrapping machine due to the size of the reel.
In the above, we mainly conducted preliminary research and discussion on the production process of roll-to-roll holographic positioning hot + convex hot cigarette packs based on relevant tests. There may be many problems that need to be solved in future mass production, but this If a new hot stamping process can be realized in batches in production, it will receive better results for improving production efficiency, saving raw materials, and promoting energy saving and emission reduction.
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