Several questions about the development of gravure printing machine
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The development of gravure printing technology in China started late. In the 1980s, in order to change the backwardness of China's packaging technology, second-class packaging, third-class prices, the relevant departments increased the development of packaging technology, so that the printing technology has developed rapidly, thus gravure Advances in technology have provided good conditions. After nearly 20 years of hard work, China's gravure printing process is relatively mature, the equipment is relatively advanced, and has a certain scale. Its importance is second only to the lithographic printing and the second largest printing method, and it plays an important role in China's printing industry.
1. Gravure market
In the past 20 years, China's gravure printing technology has developed to a certain extent. By 2000, gravure printing accounted for about 10% of the printing industry; in packaging printing, gravure printing accounted for 19%, mainly concentrated in the printing of flexible packaging materials. Paper container packaging printing. Among the cigarette packaging and printing, the proportion of gravure printing is about 30%; plastic film printing is almost entirely gravure.
2. Plate making technology
Generally speaking, China's gravure printing plate technology is mainly based on imported equipment. Due to the complicated process of traditional carbon paper corrosion gravure plate making process, long plate making cycle, high plate making quality, and large pollution, so from the 20th century In the middle of the year, foreign countries introduced and promoted the spray-etching gravure and electronic engraving gravure plate-making technology, which laid a good foundation for the development of gravure printing technology in China. Now, according to incomplete statistics, the country has imported more than 400 electronic color separation machines and more than 50 electronic engraving machines. In addition, it has introduced advanced technology such as gravure etching gravure cloth Meilan plate making system, no film electronic engraving system and laser engraving system. Plate making technology. It can be recognized that the gravure plate-making technology in China has reached the world level, and its plate-making ability can meet the market demand.
3. Gravure printing machine
According to the form of the substrate, the gravure printing machine can be mainly divided into a web gravure printing machine and a single paper gravure printing machine.
Web gravure presses include two types of unit gravure presses and satellite gravure presses, mainly for paper printing and plastic film printing.
So far, the country has introduced more than 420 gravure printing lines, including printing, compounding, slitting and bag making. Among them, the printing speed of medium-to-high-end multicolor gravure printing machines is generally above 250m/min, and most of them are used for package printing. Foreign manufacturers mainly include Bobst in Switzerland, Chambon in France, Stevenson in the United States, Serudi in Italy, and All India in Australia. The users who introduced foreign equipment were mainly Changde Quanpeng Gravure Printing Co., Chongqing Huacai Printing, Shanghai Tobacco Printing Factory, Shaanxi Jinye, Yunnan Qiaotong, and tobacco packaging printing companies in Kunming and Zhanjiang. These devices have played an important role in the printing of cigarette packets in China.
In addition, in order to meet the requirements of plastic film printing, the mid-range multi-color gravure printing machine has also been introduced from abroad, and the printing speed is generally about 200 m/min.
In order to meet the needs of packaging and printing for small and medium-sized enterprises, there are about 15 printing companies in China producing medium and low-grade web gravure printing machines, mainly in Beijing, Shaanxi, Guangdong, and other places, such as Beijing Printing Machinery Research Institute and Shaanxi Northwest. Xi'an Qinhua, Hei Niu, Xinda, Winbond and Zhongbao; Guangdong's Shantou, Zhongshan Songde and Jiangnan, Shantou Huaying, Shunde's Debao, Shenzhen's Fengtai; Zhejiang's Zhe Ning, Xinda Warm spirit and Ryan, Deguang and so on. The total production of gravure presses is about 300 units.
Sheetfed gravure presses are mainly used for high-end samples, magazines, carton printing, and securities printing including banknote printing. With the split as the standard model, the printing color number has a monochrome machine and a two-color machine, and three or four color machines can be configured according to user requirements.
For more than a decade, it has mainly imported and paper gravure printing machines from Germany's Moog Printing Machinery Co., Ltd. and Japan's Mitsubishi. Because of its high price, it is mainly introduced by the well-funded cigarette pack printing and printing bank, and it is estimated that more than 20 units will be introduced.
In recent years, according to market demand, China began to research and develop sheetfed gravure presses. The main manufacturers include Beiren Group Company, Beijing Haohengli Printing Machine Co., Shanghai Ziming Machinery Company, Shanghai Hairun and Shanghai Electric Group Printing Machine. Companies, etc., the total output is about 200 units, the market prospects are promising.
Although China's gravure printing technology has developed greatly, it has a large gap compared with the world's advanced level. It is mainly summarized in the following aspects.
1) The product technology level is low. At present, the foreign gravure printing machine has a high level of technology, mainly including the following three points:
Excellent working performance: the printing speed of the web gravure printing machine is mostly below 200m/min, the printing speed of the single-sheet gravure printing machine can be stabilized at 10,000 sheets/hour, and the overprinting precision is generally not more than 0.1mm in the main part.
High degree of automation: Minimizes downtime, maximizes machine productivity, and has high productivity.
When the printing speed of the web gravure printing machine exceeds 100m/min, most of them are equipped with printing quality inspection systems, such as printed image observation system, automatic defect detection system and 100% automatic detection system. Some manufacturers also have a gravure printing system, and the CPS monitoring system of the central gravure printing machine is a yellow type. This is an effective measure to ensure the quality of printed products, reduce the rate of paper loss, and reduce printing costs.
In contrast, the domestic gravure printing machine has lower working performance, the printing speed is mostly at the middle and low speed level, the overprinting precision is in accordance with international regulations, and the main part of the packaging and decorating gravure printing is 0.3, the automatic smashing procedure and the printing quality inspection. The technology is backward, which is the main reason for low productivity, poor quality stability and high printing costs.
2) The level of professional production is backward
Effectively organizing specialized production is the only way to improve product technology, ensure product quality, and reduce costs. In this regard, many foreign manufacturers have set an example for us. For example, the sheet paper gravure printing machine produced by the German company Moger Printing Co., Ltd., the paper feeding parts are provided by Heidelberg. For example, the automatic tension control system of the web gravure printing machine, the automatic registration control system and the automatic quality inspection system for printing products are also provided by specialized production enterprises. China's printing machine manufacturing industry has long been accustomed to large, all or small and full production mode, especially the enterprises of similar products are often closed to each other, and the results will inevitably lead to heavy burdens and mutual constraints, it is difficult to gain complementary advantages. Develop together. If we carefully investigate how many parts of the gravure printing machine produced by China's gravure printing machine manufacturing enterprises are provided by professional manufacturers, we will understand the backwardness of China's specialized production level.
3) Gravure pollution is serious
In the three main printing methods of offset printing, flexographic printing and gravure printing, the pollution caused by gravure printing is the most serious. In order to reduce pollution, the foreign printing industry has taken effective measures and achieved good results. For example, the carbon paper corrosion gravure plate-making process that has been severely punished by pollution has been eliminated; in the process of pre-processing of the plate cylinder and the gravure etching gravure and electronic engraving gravure, the treatment of the waste liquid is strengthened to reduce the pollution of gravure production; In the printing of enamel printing, gravure water-based inks have been successfully developed in the mid-to-late 1990s. All paper printing uses gravure water-based inks, and plastic film printing also does not count as surface-based inks. This is a foreign gravure printing that cannot currently maintain 15% market. The main reason for the share.
At present, the waste liquid treatment in the process of pre-processing and gravure printing of the plate cylinder is slow and slow; in printing, whether the paper gravure is not a plastic film, the price of the imported water-based ink is too high, and basically the solvent is used. Gravure ink.
Solvent-based gravure ink is an important source of gravure printing. For example, in the process of ink production, chlorocarbons are released to pollute the atmosphere and destroy the earth's ozone layer. During use, toxic substances are emitted, which is detrimental to human health and is flammable and explosive. The danger of the organic solvent remaining on the surface of the printed product may be directly contaminated by the coating on the package. As a result, the world's water-based gravure inks have replaced solvent-based gravure inks as a basic requirement for gravure printing, especially for cigarettes, wine, pharmaceutical packaging and food packaging printing. It can be seen that the promotion of the use of water-based gravure inks is urgent.
Thinking after entering the WTO
2002 is the first year of China's accession to the WTO. Joining the WTO provides opportunities for the development of gravure printing technology in China, but it also brings new challenges. In particular, China will allow foreign-owned enterprises engaged in packaging and printing to enter the Chinese market. They have advanced technology and equipment, strong capital and scientific management, which will bring great pressure and impact to the domestic gravure printing market. Due to the introduction, we must vigorously carry out organizational adjustments of enterprises, avoid low-level redundant construction, increase investment in research and development of new products and new materials, and provide much-needed gravure equipment and materials for the domestic gravure printing market. Work in several ways.
1. Grasp the organizational adjustment of the enterprise
In the next period, the focus of organizational adjustment of China's gravure printing enterprises should focus on two aspects:
1) Solve the large, comprehensive, small and comprehensive production mode of the enterprise and develop specialized socialized production.
The current organizational structure of gravure printing enterprises in China, especially gravure printing machine manufacturing enterprises, mostly belongs to the olive type mode, that is, the middle part is light and heavy: the production of parts and components of the products is almost entirely produced by the internal production of the enterprise, and the proportion is too large; The product development capability of life and the ability of marketing and after-sales service are too weak, and the proportion is too small. In this way, the competitiveness of the product will inevitably be weakened. After the adjustment of the organization, the olive-type business model will be transformed into a dumbbell-type business model, that is, the enterprise will only complete a small number of parts production and product assembly, and will have a larger proportion. The production of parts and components is turned to the society, which is undertaken by socialized and specialized manufacturers, with emphasis on product R&D, marketing and after-sales services to enhance the competitiveness of enterprises.
2) Realize mergers, reorganizations and alliances, and form three small enterprises.
At present, the domestic printing machine industry has initially completed mergers and acquisitions, and there are three enterprises that have been reorganized and united. Beiren Group and Shanghai Printing and Packaging Machinery Co., Ltd. acquired Japan’s Akiyama Corporation and Jingdezhen Printing and Packaging Machinery Co., Weihai Printing Machinery Co., Ltd. and Tangshan Yuyin. The four companies, including Changchun Printing Machinery Factory, have achieved the strong joint formation of Lianqiang Printing Machinery Group, which is the first step in the adjustment of enterprise organization. After a period of practice, constantly summing up experience and constantly improving it, we will certainly receive good results.
At present, there are about 20 domestic manufacturers of gravure printing machines, which are basically large and small and full production modes. There are different levels of technology and repetitive production to varying degrees. If advanced and necessary enterprise mergers, reorganizations and alliances are formed according to their respective advantages, and gradually form three small enterprises, namely small, specialized, small, fine, small and strong enterprises, the product technology level can be greatly improved, the production scale can be expanded, and market competition can be enhanced. force.
2. Development of high-end gravure printing equipment to limit the production of low-end gravure printing machines
Generally speaking, at present, China's domestic gravure printing machines and digital products are close to the mid-range technical level, and most of them belong to the middle and low-end products. From the perspective of market demand, there are currently too many low-end gravure presses in China, and there are not enough high-end gravure presses. In order to change this situation, the following three points are proposed:
1) Encourage the development of medium and high-grade web gravure presses.
In order to slow down the passive situation of medium and high-grade web gravure printing machines, the state-owned and relevant departments should give encouragement and support to enterprises that develop such products in order to gradually increase the market share of domestic high-end gravure printing machines. .
2) Make necessary restrictions on the production and use of low-end gravure presses.
In the packaging and printing enterprises, a considerable number of small and medium-sized enterprises in China now have backward equipment, low quality of printed products and serious pollution. In particular, the working environment of many enterprise workers is very bad. Such enterprises that waste materials, consume energy, and are seriously polluted are unfavorable to the country. At present, many domestic enterprises have gradually implemented the ISO14000 international standard and imposed strict restrictions on the production and use of such products.
3) Increase the intensity of research and development of sheetfed gravure presses.
Paper container printing is one of the main markets for gravure printing, especially for high-volume cigarettes, wine, medicines and cosmetics. Most of the packaging printing is a small batch, multi-variety, high-quality typical example, and the single-sheet gravure printing machine and concave Combination gravure printing combined with offset or flexo printing is the best choice for printing this type of product. Therefore, increasing investment in the development of sheetfed gravure presses will play an important role in stabilizing and expanding the gravure market.
3. Accelerate the pace of research and development of gravure water-based inks, adapt to the new situation of WTO entry
As described above, the replacement of solvent-based inks with aqueous inks has become an inevitable trend in the development of gravure printing. If it is not possible to use the solvent-based inks for the water-based inks required by the gravure market as soon as possible, then these prints will not only enter the international market, but the existing gravure market in China will also be wholly foreign-owned. Shock. Therefore, the development of gravure printing technology in China must accelerate the development of gravure ink.
At present, there are more than 300 ink factories in China, including 6 manufacturers with an annual output of more than 5,000 tons. In 2001, the total national ink production was 200,000 tons. Although the development of gravure aqueous ink has begun, it has not yet formed a certain scale of production. According to the current market share of gravure printing, the country needs about 20,000 tons of gravure ink per year. Therefore, the task of eliminating solvent-based gravure inks and promoting and using water-based inks is still very arduous. As long as the industry pays attention to it, increases R&D investment, and organizes it carefully, it can provide the required water-based ink for the gravure printing market and make important contributions to the development of gravure printing technology in China.