In the printing production process, various faults will be encountered. Some of the faults are the same, but the reasons are different. "The shape is similar and the god is not like", so the method of solving the problem is not the same. This requires careful analysis, finding the right reasons, and solving the problem in a targeted manner. The author uses two specific failure cases to explain the importance of the right medicine.
Case
Equipment failure caused by film anti-stick
I have encountered such a failure in the production process. When printing a seven-color product, the gravure printing machine occasionally shows a slight anti-stick phenomenon in the film after printing. This product is a regular product of the factory and no such phenomenon has occurred before. When the technician arrived at the scene, the ink, materials, and production process were repeatedly compared and tested accordingly, but the printed product did not have any problems, and the problem occurred when the batch was produced. Therefore, the technician thinks that the drying system of the printing press has failed, and this problem is thrown into the hands of the equipment maintenance personnel. When the maintenance personnel arrive at the scene, the printer's oven and its guide sticks, heat exchangers and steam traps, heating control system and instrument and electric valve, air supply fan and air volume are inspected and tested. The results are in good condition and tested. The parameters are within the normal range. The whole system does not see a problem, but anti-sticking still occurs.
Finally, a careful analysis of the film anti-adhesive condition on the winder revealed that about 500 meters of the product in the printed matter of about 6000 meters had anti-sticking, and from the slight anti-sticking which is not easy to find, to the visible anti-sticking, It is a process of gradual development to disappearion. The biggest possibility of this situation is the accidental failure of the temperature control system. The probability of problems with the thermocouple and the electric valve control device is high, so the thermocouple is replaced, but this phenomenon happens occasionally, and the electric valve is replaced. After the controller, after a period of observation, no anti-sticking occurred, and the problem was solved.
Case
Solvent volatilization
The second failure case is that when I use a special gravure printing machine for thermal transfer film production, irregular white spots are found on the coating layer, which is a problem that often occurs when producing such varieties. The operator adjusted the humidity of the plate roller and the dry hot air according to the general treatment method, but the white point phenomenon could not be solved. When the technician arrives at the scene, he thinks that the problem may be the amount of coating and the moisture content of the hot air. By adjusting the coating amount by changing the plate roller and changing the moisture content of the hot air, the test is repeated dozens of times. The situation has changed, but the problem cannot be solved fundamentally.
Under such circumstances, the technician judges that there is a problem with the drying system of the device and requires the equipment department to solve it. After the equipment maintenance personnel arrived at the scene, the equipment, the heat exchanger, the steam valve, the temperature control system instrument and the electric valve, the humidifier, the fan and the air volume were carefully checked according to the usual method. The equipment parts were in good condition and work. Normal, the air volume, humidity, and temperature are all within the control requirements, and the equipment problem can be basically eliminated.
Finally, through the analysis of the samples, it is found that these white spots occur in all parts of the product, and the problems are universal, so the problems of materials and coating liquids should be considered. After replacing the materials of different manufacturers, the problem remains. Therefore, the coating liquid supplier was tested on it, and it was found that the solvent evaporation rate of the batch coating liquid was significantly higher than that of the original coating liquid, and the coating liquid was replaced in time before production, and white spots did not occur again.
(Author: Shanghai Toppan Co., Ltd.)
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