Exploring the root cause of the quality of the perfect binding
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In recent years, with the acceleration of the publishing rhythm, the number of books using flat-packed wireless glue-bonding is increasing. According to incomplete statistics, the books printed in China in the past two years are roughly in the billions of books, including more than 40. The 100 million copies are processed into a book using wireless adhesive binding. The thermal bonding material EVA hot melt adhesive used in bonding books and magazines uses nearly 10,000 tons per year; there are more than 100,000 units for bookbinding using such adhesive materials; the wireless adhesive binding equipment only has a linkage production line. Hundreds, there are more than 2,000 units. The processing of the book by the adhesive binding process, the use of the dry material, involving the wide range of processing units, has never been seen in the history of bookbinding. However, it can not be seen that the quality of book binding has been found to be more serious from the quality inspection of books in recent years. According to relevant parts, the non-conformity of binding is about 65% of the total quality of printed products, including wireless adhesive. The non-conforming products caused by the order processing accounted for more than 80%, and the unqualified products mainly reflected from the surface, after the processing of the book, the page fell, the back of the book was uneven, the book block was broken, the bubbles, the holes, the glue, etc. Where does the reason come from? Now we analyze from the following points, so that the relevant units can find out the reasons in the actual management work, solve them, and improve the quality of the perfect binding processing.
1. Insufficient understanding of the importance of changes in the post-press binding process
The post-press binding process is the final decoration process of the whole process of the printing process, and it is also the final finishing process of the book processing. It is related to the preservation value and reading value of the printing product, and affects the above two processes (pre-press, printing). The processing effect and the guarantee of the cycle; no matter how good the printed products are, there is no correct and firm connection, beautiful outer packaging. It also does not reflect the value of printed products. Post-press binding is a very important process in the final packaging of the print.
For a long time, people have always had a prejudice against this process. They believe that anyone can do the job, but ignore the importance of it. At the same time, it also causes the cultural quality of the people who have been engaged in this work for many years to be lower than the prepress and printing process. As for the largest printing professional school in Asia, such as Beijing Printing Institute, it has not been bound for a number of specialized disciplines in the printing industry for many years. Only in recent years, there are some post-binding courses (within the packaging and decoration department). . In the large-scale printing information meeting, the printing scientific research meeting generally pre-presses and prints. For example, only the pre-press and printing and printing products complete the mission, and the books can be read without being booked. This situation will continue, will the quality of book binding not increase? The high quality of book decoration will affect the overall image of book publishing in China, so it must be really noticed.
Post-press binding is a processing process with complicated equipment, complicated technology, many kinds of materials and great changes. There are dozens of equipments, more than 100 models and forms, and nearly 10 types of linkage production lines. Each line has a different model and form, and there is almost no commonality between the stand-alone equipment between the types of work. Post-press binding has evolved from a manual process to a modern process of mechanization, linkage, and automation equipment.
The post-press binding process is more complicated and has a large change. There are more than 10 types of loading methods. There are more than 30 processes in the process of loading, and there are many changes in the process. How do publishers ask how to process them for binding? The ability to meet the requirements is rarely valued.
There are hundreds of styles of materials to be bound, and each material involves a lot of knowledge. For example, there are more than 10 cover materials, and the textures are different. These different materials are in turn related to the use of bonding materials. The difference in the dry knots is related to the firming effect of the dead objects and the dead knots. Whether the material is used correctly or not directly affects the firmness and shelf life of the book. At present, the quality problems arising from wireless adhesive binding are directly related to the use of EVA hot melt adhesives.
In short, the post-press binding process is not only a complicated processing process but also an art processing process. Today's books are not only a reading, but also a gift, a work of art, and a valuable preservation. It not only adds knowledge to humans, but also Bring people artistic enjoyment.
Therefore, the effect and value of the printed products must be expressed in terms of the quality of the printed binding. For our staff engaged in book publishing, production and other aspects, we must clearly understand the complexity of this process, the importance and the overall concept of making a book, and re-understand and understand this process for publishing high-quality books.
2, the equipment has changed, the quality of personnel has not changed.
Modern post-press binding equipment has entered a period of mechanization, automation and linkage production. Especially after the mid-1990s, China has entered the third period of change of binding equipment, which is characterized by everything moving closer to international standards. At present, there are about 100 large-scale linkage production lines in China, and the most advanced linkage line has a price of nearly 20 million RMB. Computer control, image display, etc., the equipment is getting higher and higher, and these equipment management and operation requirements have a certain level of technology. Management and operations personnel are competent. However, it is understood that there are very few talents in this area in China, and the existing skilled workers are far from meeting the expected requirements; generally, the equipment is coming, and some units only let the personnel train for a few days to operate on the machine. Most of the equipment is used to touch the dry machine and can be turned up. Therefore, the life of the equipment is shortened, the efficiency cannot be improved, the quality of the finished product can not meet the standard requirements, and the problem is not clear, the equipment complaining is not looking for The reason for people; as far as the quality of the team in the post-press binding process is concerned, most of them are not graduated from professional schools, or even have not conducted any training. How can this be adapted to today's modern production? The equipment has become more advanced, and the quality of people has not changed. How can we keep up with the trend of the times?
3, the process materials have changed, and the environmental conditions have not changed.
As far as the wireless adhesive bonding process is concerned, almost every book processing factory has to be involved. The majority of the cementing materials used in this process are thermoplastic EVA hot melt adhesives, which are environmentally and conditionally demanding when used. At the Sino-German Binding Technology Training Course organized by Nanjing Aide Printing Co., Ltd., the German teacher Mr. Starr put forward the importance of environment and conditions when explaining the use of EVA hot melt adhesive, and introduced the EVA hot melt adhesive in France. The temperature and humidity of the workshop room for processing books have certain data control. The temperature is controlled between 19 °C and 25 °C, and the humidity is controlled at 50% RH. However, China generally requires the temperature in the wireless binding production workshop to reach 17 °C- Between 30 ° C; this requirement is twice as good as abroad. However, except for a small number of units and regions that can be achieved, most of them cannot be implemented according to this requirement. For example, the temperature in the south of China is high, and there are many units in the binding shop where there is no constant temperature or air-conditioning temperature. The temperature is as high as about 38 °C, which causes the curing time of the glue to be prolonged, the hardening and setting, and the linkage production line cannot be cut. In the north, when the temperature is low in winter, the indoor temperature is the lowest (no constant temperature, air conditioning equipment) to about 10 °C, which causes the hot melt adhesive to be cured before it can be bonded. As for the temperature, the difference is due to the dry area. The standardization of the enterprise is not perfect (the general binding shop has no humidity meter device), and it is even more demanding to achieve the expected humidity standard; for example, the area with much rain in the south of China is humid and humid, and the humidity in the workshop is about 80% RH, while the north The area is less dry and the humidity is as low as 30% RH. Too low and too high humidity have a direct impact on the bonding between paper and books, which will cause various quality problems in the wireless adhesive staple box.
In order to improve the quality of book binding. In the binding shop, especially for hot melt adhesive materials such as EVA, it is necessary to create a good environment and conditions for standardized production.
4. Insufficient understanding of modern bonding materials
There are two kinds of bonding materials used for binding, one is cold hydrosol; the other is thermoplastic glue, which is divided into osmosis, suction and half by heat-melt and bonded by adhesive material. Permeable (also known as semi-attractive), the three types of bonding materials and the type of the object to be bonded are different, and the bonding effect is also different.
China's binding bonding materials have long used more cold glue, cold glue is a water solvent, and its drying method is shaped by heating and pressing with temperature and time.
The thermoplastic glue commonly used in modern times is different, such as EVA hot melt adhesive, which is a solid moisture-free fusible material. The material is passed through a suitable melting point (softening) temperature and temperature. , open time, curing time and cooling hardening time, and then correctly clamped and shaped, can achieve the reliable effect of dry knot. Because EVA hot melt adhesive is affected a lot when used, such as the temperature and humidity of the plant, the speed of the running speed, the difference of the paper texture, the different adhesives and side rubber, the temperature of the glue, etc. There are direct relationships between good and bad.
In addition, there are many publishers that require the thickness of the backing of the processing factory to be as large as possible. It is considered that the more the smearing is, the stronger it is. This is a misunderstanding. In fact, the fastness of the book joint is in a certain sense. Firmness is irrelevant. Because the strength, viscosity, viscosity, etc. of the adhesive can determine the fastness of the book bond. As long as the strength, viscosity, and viscosity of the book backing meet the standard requirements, the adhesive layer should be “thin and uniform”: the thickening of the book backing can only cause the back of the book to be uneven, difficult to read, ugly appearance and waste of rubber.
There are many types of cold and hot glue used for binding. Among them, EVA hot melt adhesives have different bonding effects due to different sources of basic materials, different types of auxiliary materials and different price of various ingredients. Therefore, we must fully understand the various materials used in modern use (including cover materials, cardboard, etc.), strengthen learning, understand it theoretically and then apply it to practice, record and use the experience at any time, and summarize the ascending theory. Improve and achieve the desired requirements.