Second, gravure printing
Gravure printing is a printing method with excellent gradation performance, correspondence with various substrates, seamless image printing, and good print quality stability. In Europe and the United States, the development of publishing and printing with the aim of mass production as the main body has developed. In Japan, the use of package gravure as the center has become popular.
Packaging gravure is made of paper, cellophane, plastic, plastic film as printing material, printing quality is high, and a wide range of solvent types are used depending on the printing materials. Therefore, compared with cheap flexographic printing in Japan, the gravure of packaging has been widely used. universal. The Japan National Gravure Cooperative Syndicate Federation, consisting mainly of professional gravure printing companies, has 200 corporate members, most of whom are packaging gravure companies.
Gravure printing was heavily invested in environmental protection equipment such as printing machines and plate-making equipment, and the recovery of heart solvents. In Japan, there are about 60 publishing gravure printers that are mainly used by large companies. Its print level performance is unmatched by other printing methods.
(I) Publishing Gravure Printing
Although published gravure has a sheet-fed gravure printing machine for printing art books, the mainstream of publishing gravure printing is a high-speed web rotary gravure printing machine suitable for large-volume printing. From a global point of view, high-speed wide-format machines with high-volume and low-cost targets have made progress, with a maximum speed of 17 meters per second and a roll width of 2450-3480mm.
In Japan, although a 2,450mm wide device has been introduced, compared with Europe and the United States, Japan's publishing market is small and multi-variety and small-batch, so the mainstream width is 1900mm. Publication Gravure has begun to compete with offset printing. Existing problems include reducing costs, improving quality, and taking environmental measures.
Gravure printing system
The biggest feature of the gravure printing press is that, by changing the diameter of the paper web and the plate cylinder, it is possible to produce folded signatures of various sizes and page numbers. The gravure machines produced by Aruba (Germany) and Cerruti (Italy) occupy absolute market share. Japanese manufacturers such as Toshiba Machine and Japan Seiko are also producing.
Paper feeding department. Since it is a high-speed printing, a high-speed gluing and splicing device that is synchronized with the rotation speed of the paper roll is generally used.
Crew department. The gravure printing is to physically transfer the ink filled in the concave part of the plate cylinder to the substrate, and each color should be dried (mainly using hot air drying). A variety of inks can be used and printed on a variety of substrates. The gravure printing uses a simple direct printing method, so the stability is good and the printing quality is consistent. Due to the long paper path, tension control and print registration become difficult.
Folding machine. Folding machines are models with adjustable size and number of pages. Unlike an offset press, the diameter of the plate cylinder is variable, and the folding machine accordingly also changes the folding size. The printed tape is cut into narrow tapes. By changing the position of the knife, the size of the print head can be changed. The size of the cut direction is changed by changing the position of the fold by changing the phase of the teeth and the folding knife on the folding roller. At this time, the phase of the cutting roller is changed so that the folding machine can fold out the signatures that are afraid of the specifications.
2. Environmental protection equipment
Solvent recovery device: A recovery device that uses activated carbon to absorb the solvent gas generated during production. Toluene solvents must not be discharged outside and must be 100% recycled. The device will reuse the recovered solvent to reduce the cost of using the solvent.
Air conditioning equipment
Like offset printing, the control of temperature and humidity is very important for the gravure shop environment, especially when the temperature and humidity change drastically, it will inevitably have a great influence on the printing register. From a solvent concentration point of view, gravure room ventilation management is a must. Solvent recovery equipment can be used to limit solvent gas emissions near the unit. Considering the exhaust gas volume and the amount of air supply including the air conditioner, it is necessary to design the entire plant to prevent the accumulation of solvent gas.
4. Auxiliary equipment
For today's high-speed gravure presses, the following auxiliary equipment is indispensable: 1 Overprint control device. Without it, the current gravure printing cannot be carried out. 2 ink viscosity control device. Measure ink viscosity, adjust the amount of solvent added, and automatically adjust the viscosity of the device. 3 electrostatic printing device. Devices that use static electricity to help transfer ink. It is essential for engraving gravure and high-speed gravure. 4 quality inspection device. Now the quality requirements have increased, and even the products printed on the web have to be checked one by one. Current inspection devices cannot detect the problem of squeegee marks and need to be developed.
5. Ink
Gravure printing, like offset printing, also uses four-color inks for printing. A great difference from offset printing is the use of low-viscosity toluene solvent inks, so gravure does not suffer from problems such as offset printing due to the high viscosity of the ink leading to breakage of the paper. Due to the use of low-boiling solvents under high-speed drying conditions, high-priced solvent recovery devices and explosion-proof devices need to be used. The disadvantage of the commonly used gravure inks is the use of organic solvents. The water-based and non-toluene-free inks are important for both gravure printing and gravure printing. However, gravure printing uses only toluene solvent, and its recovery technology has been established. It has been widely used in gravure printing plants. Evaporated solvent is recycled. In order to recover completely, it is necessary to prevent the discharge of solvent gas outside the workshop and it must be prevented from leaking to the workplace. Therefore, a countermeasure for completely sealing off the part using the solvent and achieving complete recovery of the solvent is being put forward. The biggest remaining problem is to reduce costs.
6. Future trends
The future development is mainly determined by the publishing market and the postal advertising market. For gravure printing of high-volume products, it can play its specialty, but from the status quo in Japan, it cannot be considered that the market will generally expand. Therefore, when gravure printing competes with offset printing for the market, it should aim at fully reducing costs, so that prints can achieve rich levels of performance and high contrast.
Gravure printing is a printing method with excellent gradation performance, correspondence with various substrates, seamless image printing, and good print quality stability. In Europe and the United States, the development of publishing and printing with the aim of mass production as the main body has developed. In Japan, the use of package gravure as the center has become popular.
Packaging gravure is made of paper, cellophane, plastic, plastic film as printing material, printing quality is high, and a wide range of solvent types are used depending on the printing materials. Therefore, compared with cheap flexographic printing in Japan, the gravure of packaging has been widely used. universal. The Japan National Gravure Cooperative Syndicate Federation, consisting mainly of professional gravure printing companies, has 200 corporate members, most of whom are packaging gravure companies.
Gravure printing was heavily invested in environmental protection equipment such as printing machines and plate-making equipment, and the recovery of heart solvents. In Japan, there are about 60 publishing gravure printers that are mainly used by large companies. Its print level performance is unmatched by other printing methods.
(I) Publishing Gravure Printing
Although published gravure has a sheet-fed gravure printing machine for printing art books, the mainstream of publishing gravure printing is a high-speed web rotary gravure printing machine suitable for large-volume printing. From a global point of view, high-speed wide-format machines with high-volume and low-cost targets have made progress, with a maximum speed of 17 meters per second and a roll width of 2450-3480mm.
In Japan, although a 2,450mm wide device has been introduced, compared with Europe and the United States, Japan's publishing market is small and multi-variety and small-batch, so the mainstream width is 1900mm. Publication Gravure has begun to compete with offset printing. Existing problems include reducing costs, improving quality, and taking environmental measures.
Gravure printing system
The biggest feature of the gravure printing press is that, by changing the diameter of the paper web and the plate cylinder, it is possible to produce folded signatures of various sizes and page numbers. The gravure machines produced by Aruba (Germany) and Cerruti (Italy) occupy absolute market share. Japanese manufacturers such as Toshiba Machine and Japan Seiko are also producing.
Paper feeding department. Since it is a high-speed printing, a high-speed gluing and splicing device that is synchronized with the rotation speed of the paper roll is generally used.
Crew department. The gravure printing is to physically transfer the ink filled in the concave part of the plate cylinder to the substrate, and each color should be dried (mainly using hot air drying). A variety of inks can be used and printed on a variety of substrates. The gravure printing uses a simple direct printing method, so the stability is good and the printing quality is consistent. Due to the long paper path, tension control and print registration become difficult.
Folding machine. Folding machines are models with adjustable size and number of pages. Unlike an offset press, the diameter of the plate cylinder is variable, and the folding machine accordingly also changes the folding size. The printed tape is cut into narrow tapes. By changing the position of the knife, the size of the print head can be changed. The size of the cut direction is changed by changing the position of the fold by changing the phase of the teeth and the folding knife on the folding roller. At this time, the phase of the cutting roller is changed so that the folding machine can fold out the signatures that are afraid of the specifications.
2. Environmental protection equipment
Solvent recovery device: A recovery device that uses activated carbon to absorb the solvent gas generated during production. Toluene solvents must not be discharged outside and must be 100% recycled. The device will reuse the recovered solvent to reduce the cost of using the solvent.
Air conditioning equipment
Like offset printing, the control of temperature and humidity is very important for the gravure shop environment, especially when the temperature and humidity change drastically, it will inevitably have a great influence on the printing register. From a solvent concentration point of view, gravure room ventilation management is a must. Solvent recovery equipment can be used to limit solvent gas emissions near the unit. Considering the exhaust gas volume and the amount of air supply including the air conditioner, it is necessary to design the entire plant to prevent the accumulation of solvent gas.
4. Auxiliary equipment
For today's high-speed gravure presses, the following auxiliary equipment is indispensable: 1 Overprint control device. Without it, the current gravure printing cannot be carried out. 2 ink viscosity control device. Measure ink viscosity, adjust the amount of solvent added, and automatically adjust the viscosity of the device. 3 electrostatic printing device. Devices that use static electricity to help transfer ink. It is essential for engraving gravure and high-speed gravure. 4 quality inspection device. Now the quality requirements have increased, and even the products printed on the web have to be checked one by one. Current inspection devices cannot detect the problem of squeegee marks and need to be developed.
5. Ink
Gravure printing, like offset printing, also uses four-color inks for printing. A great difference from offset printing is the use of low-viscosity toluene solvent inks, so gravure does not suffer from problems such as offset printing due to the high viscosity of the ink leading to breakage of the paper. Due to the use of low-boiling solvents under high-speed drying conditions, high-priced solvent recovery devices and explosion-proof devices need to be used. The disadvantage of the commonly used gravure inks is the use of organic solvents. The water-based and non-toluene-free inks are important for both gravure printing and gravure printing. However, gravure printing uses only toluene solvent, and its recovery technology has been established. It has been widely used in gravure printing plants. Evaporated solvent is recycled. In order to recover completely, it is necessary to prevent the discharge of solvent gas outside the workshop and it must be prevented from leaking to the workplace. Therefore, a countermeasure for completely sealing off the part using the solvent and achieving complete recovery of the solvent is being put forward. The biggest remaining problem is to reduce costs.
6. Future trends
The future development is mainly determined by the publishing market and the postal advertising market. For gravure printing of high-volume products, it can play its specialty, but from the status quo in Japan, it cannot be considered that the market will generally expand. Therefore, when gravure printing competes with offset printing for the market, it should aim at fully reducing costs, so that prints can achieve rich levels of performance and high contrast.
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