Environmental issues hinder the development of the gravure printing industry but also promote its transformation and upgrading
With the development of the times and the improvement of technology, today, gravure printing, which has made great contributions to the packaging industry, has faced the challenges and baptism of the market after experiencing rapid development in the past 20 years: Environmental protection is a major issue facing gravure printing. As early as 20 years ago, European countries and European countries enacted legislation to protect the environment, and made regulations and restrictions on VOC emissions. In China, VOC emissions control has just started and many problems need to be resolved; the requirements for developing clean energy and reducing energy consumption are within the industry. Increasingly loud voices; equipment should be more intelligent; market demand for equipment efficiency, work environment is increasing; customers require the entire production process to control the entire process; "quantitative value" is the customer evaluation, determine their investment Approaches... These seemingly intricate and complicated issues, but after careful analysis and conclusion, it can be concluded that the development trend of gravure printing is: environmental protection, energy saving, and smart factories.
In 2012, the State Council formally approved the 12th Five-Year Plan for Prevention and Control of Atmospheric Pollution in Key Regions. It was the first time that VOC pollution control was an important part of the environmental impact assessment of construction projects. For the first time, VOCs treatment and emission reduction were clearly defined in national documents. purpose. The "Planning" mentioned that "control of volatile organic pollutants as an important part of the environmental impact assessment of construction projects, adopt strict pollution control measures," and put forward key control areas and key emission companies, enterprises in key regions, will be subject to strict Monitoring and management. The recent introduction of a series of national and local laws and regulations, is the sword refers to the printing industry, such as Beijing, the existing printing companies, each use 1 ton of solvent plus 2000 to 2500 yuan of sewage charges; Shanghai, will be this year At the end of the year, VOC emissions from the printing industry are banned; in Jiangsu, the emission of VOCs from the printing industry will be banned in mid-2016. These stringent regulations are promoting industry product upgrades and corporate transformation.
Treatment methods for VOCs include recovery and RTO thermal oxidation, but China's related technologies are not very mature, there are still many problems, such as the rapid decline in the adsorption rate, solvent acidification, safety issues, and the late separation of mixed solvents can not be resolved ,and many more. In fact, adopting a set of effective methods and high-quality equipment is the law to deal with the problem. The author believes that the process of adsorption-recovery-condensation-distillation can be performed on the discharge of a single solvent, so that high-purity solvents can be recycled, which is environmentally friendly and economically beneficial. For mixed solvents, RTO treatment can be used to recycle heat energy. In addition, prior to the implementation of the two VOCs treatment measures, the existing equipment can be retrofitted with the addition of the LEL Safety Circulator, which can reduce over 40% of VOCs recovery and RTO thermal oxidation equipment investment.
During the printing process, VOCs are discharged while also consuming large amounts of heat energy. The consumed heat energy is the latent heat of vaporization of the solvent needed to print the drying itself, and the waste heat of VOCs exhaust gas. Calculated according to the amount of solvent used in traditional printing, the theoretical heating power of a color group is 5 to 10 KW, and actually the drying power is often in the range of 30 to 72 KW or even higher. The energy consumption required for drying in the printing industry accounts for 2% to 5% of the total product cost, while the profit of the traditional printing industry is also maintained at this level. Therefore, if there is a certain technology, the drying energy consumption of the traditional printing can be reduced. Half, then it means that the company's profits will double. In the application of energy-saving measures, Shaanxi Beiren has taken the lead in introducing two efficient energy-saving methods in China: heat pumps and heat pipes. When the drying temperature required for printing is lower than 100°C, a heat pump can be used. When the drying temperature required for printing is higher than 100°C, a heat pipe is used.
Heat pumps typically save 60% to 70%. At present, 25% of the printing enterprises in the country use electricity as heating energy. If these printing companies switch to heat pumps, the national printing industry can save 1.02 billion kWh of electricity each year, which is equivalent to the total power generation of the Liujiaxia hydropower station for 2 months, equivalent to Reduce 100,000 tons of carbon dioxide. As of September this year, the national heat pump installed capacity has exceeded 1,000 units.
Heat pipe technology has been widely used in aerospace, military and other industries. Since it was introduced into the radiator manufacturing industry, people have changed the design ideas of traditional radiators.
The working principle of the heat pipe heat exchanger is as follows: the exhaust passes through the evaporation end of the heat pipe heat exchanger, one end of the heat pipe is heated, the medium liquid in the capillary tube quickly evaporates, steam flows to the other end (condensing end) under a slight pressure difference, and the fresh air passes through At the time of condensation, the medium steam in the heat pipe releases heat when cooled and recondenses into a liquid. The liquid flows back to the evaporation end along the capillary action of the porous material inside the heat pipe. This cycle is repeated, and the heat is transferred from one end of the heat pipe to the other end. . The heat transfer of the heat pipe depends on the phase change of the medium in the pipe, which is efficient and rapid, and its heat transfer efficiency can reach more than 60%. Because according to the principle of evaporation design, the higher the operating temperature zone of the heat pipe, the more obvious the energy-saving effect, and its energy-saving is usually 35% to 55%.
The smart manufacturing and smart factories that have been applied in the context of Global Industry 4.0 have been rapidly expanding. Today, many industries such as automobile manufacturing, chemicals, logistics, etc. are undergoing changes, and they are moving toward Industry 4.0 on the basis of Industry 3.0. Traditional printing companies rely on workers' skills and paper information flow for production. They are inefficient, consume energy-consuming materials, are large and unrefined, and lack market competitiveness. It can be said that China's printing industry is still in the industrial 2.x era, or even lower. Based on the characteristics of the printing industry, Shaanxi Beiren formulated a digital-based smart factory development model for the printing industry.
Printing and packaging smart factory is a complex and huge system, mainly composed of intelligent logistics system, enterprise management software, production information collection system, and intelligent production equipment. Through the collaborative work of various systems, a fully functional intelligent digital factory is built. In a smart digital factory, devices and devices are interconnected, people are connected to each other, and people are connected to devices. That is, the physical objects in the system communicate with each other in the information system and cross-border information exchange. Each system achieves cross-integration.
In the printing and packaging smart factory, printing and packaging equipment is no longer the only or independent main production equipment, but a part of the entire intelligent production process. The entire system is coordinated and intelligent dispatching is implemented—automatically transporting materials from the intelligent warehouse to the printing equipment; the operator of the printing equipment does not need to load and unwind the roll, and the intelligent equipment can automatically complete the roll-up and down; the process parameters of the entire equipment are sent by the MES system. To the device, the device automatically reads and writes and completes the parameter settings. In this way, equipment operators only perform supervision and inspection, which can reduce the number of employees in the company by 50%.
Environmental protection, energy saving and smart factories are the future development trend of gravure printing. It is believed that with the popularization of the above technologies in the industry, traditional printing companies will reshuffle and integrate, inefficient and environmentally unfriendly small enterprises will be forced to shut down and switch, and disorderly market competition will become orderly competition. Let the industry go along the path of healthy development.
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