Green Printing Teaching Series: How does gravure realize green environmental protection?

New technologies, new processes, new equipment and new materials in the gravure industry will develop rapidly in the direction of environmental protection, energy saving, emission reduction, loss reduction, and improved quality and efficiency. Under this background, a series of new technologies such as benzene-free technology, loss control, high-efficiency drying equipment, and solvent recovery began to be applied to the flexible packaging gravure industry.

Renovation and upgrading of equipment such as gravure printing

The biggest material loss in the production process of gravure printing is the waste generated during commissioning and overprinting. If the fine adjustment operations and process steps are closely linked, a stable and predictable waste value will be obtained. Domestic gravure equipment manufacturers use the latest technologies such as rapid pre-registration, high-precision tension control, etc. to make cutting losses, equipment restart losses (registered), order replacement losses, re-starting previously stored order losses, and speed reduction The loss has reached a fairly low level, even better than the international advanced level in some respects.

Under the pressure of low profit of flexible packaging products, domestic flexible packaging gravure printing companies have paid more and more attention to the material consumption indicators in the printing or composite equipment processing process (including normal roll change) in order to minimize product costs. Therefore, material loss data has become an important indicator for flexible packaging gravure companies to choose equipment.

Nowadays, the auxiliary operation time of the advanced gravure printing machine is greatly shortened. The integrated plate loading and inking cart realizes the integrated operation of plate loading, plate transportation and inking, which can clean the plate roller and ink tank offline; through the rapid inking system, the solvent is directly fed into the ink tray from the solvent room Controlled by ink viscosity controller; sleeve pressure roller technology does not require tooling replacement, labor intensity is reduced, and replacement time is greatly shortened; rapid replacement blade technology realizes rapid blade replacement; laser edge-alignment system and safety chuck quick clamping system realizes rapid Scroll up and down; fault display and alarm help maintenance personnel quickly diagnose and repair; historical fault alarm indication can reduce the time for maintenance personnel to troubleshoot.

In the gravure production process, the energy consumed by the drying oven accounts for a large proportion. The application of heat pump technology, waste heat recovery system, and layered oven effectively reduces the consumption of heat energy. The LEL-based fully automatic monitoring and drying system not only saves energy and reduces emissions, but also prevents the risk of explosion and combustion in the drying system, while greatly reducing the cost of exhaust gas treatment.

Exhaust gas treatment

There are three main ways to control VOC emissions in gravure, namely source control, process management and terminal control.

Source control is to reduce the use of organic solvents from the beginning of the printing process, so as to achieve the purpose of reducing VOC emissions. The main measures are to promote low-VOC or non-VOC environmentally friendly inks, cleaning agents and other raw and auxiliary materials, such as the promotion of water-based inks, single solvent inks, etc.

Process management refers to measures such as improving drying efficiency and production site management during the printing process to achieve VOC emission reduction. The main measures are to carry out technological innovations on the printing press to reduce the VOC air volume emitted by the production, increase the concentration, and increase the use of thermal energy. , Green printing certification, etc.

End treatment currently has two main directions, namely recovery and combustion treatment. The recovered volatile organic compounds can be directly or simply purified and returned to the process for reuse to reduce the consumption of raw materials, or used in production processes with low quality organic solvents or for centralized separation and purification. At present, some large-scale flexible packaging gravure printing enterprises have begun to recycle exhaust gas (solvent), whether it is the adsorption recovery method or the regenerative catalytic combustion method, I believe that flexible packaging gravure printing enterprises can obtain certain economic benefits and society benefit.

Benzene-free gravure ink and application of integrated ink

As the concept of environmental protection and sustainable development has become more and more popular, the relevant national environmental protection policies have shifted from the "legal compliance" stage to the strict law enforcement stage, and the requirements for environmental protection of terminal enterprises are becoming higher and higher. The benzene-free process is bound to accelerate.

A major technological advancement from benzene-containing ink to benzene-free ink and flexible packaging gravure printing industry is also another innovation of environmental protection technology in the ink industry. The backbone enterprises in the industry and some small and medium-sized enterprises have begun to use benzene-free inks. However, as far as small enterprises are concerned, benzene (toluene, xylene) inks are still the mainstay, and they are in urgent need of specification.

At present, the integrated ink has been used in large areas of some large-scale flexible packaging gravure printing enterprises, which will become an important development direction of gravure printing ink.

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