How to shorten the printing preparation time in the web printing process

Web printing speed is as fast as it can reach 3000 feet / minute. But too long printing preparation time is the biggest problem in the printing process, it will extend the working cycle of the job.

So how to reduce printing preparation time? In the single-sheet printing process, we emphasize the management, hiring, and the use of instant plate replacement (SMED) to measure the degree of improvement in the production process. Here, we give some explanations on some situations in the web printing process.

First consideration

The primary consideration is not how long it takes to prepare for printing, but a combination of issues. Must consider the preparation time, the optimization of the entire production and the synchronization of each step of the production process. At the same time, preparation time, idle time and waste of all work must be minimized. The key to successful production is to maximize production capacity while minimizing resources such as machinery and employees.

Cost affects awareness

A large number of printing workers do not understand or never realize the cost of producing a printed product, and what role they play in controlling costs. If they do not know their position in the entire production process, they will Always think about it correctly. If managers keep track of every link, all employees—from the main management staff to the underlying cleaners—have a sense of responsibility to curb costs. If there is a problem in the printing process, you should immediately analyze the cause and use a large amount of paper to waste before shutting down to eliminate the fault. Generally, the operator prefers to clear the fault in the low-speed running state.

Standardize printing preparation speed

A normal printing preparation requires about five inspection, analysis and correction processes. The most basic problem is the printing speed. For example, if after five cycles, we have already saved sheet waste. If the printing press is running at a speed of 20,000 prints per hour, there will be a waste of 5000 sheets; if we still use the same printing and the speed is 10000iph, the waste is 2500 sheets, which means a 50% savings.
As the printing press gradually reaches its target operating speed, the ink and wetting system need to maintain a good balance. This is the key to reducing waste ... But although some printers can produce qualified products, it is difficult to quickly reach the full-load printing speed from the preparation speed-this process must be carried out slowly. There are tools, such as closed-cycle inking rollers, etc., which can be used for process control to help the operator to optimize the settings of the ink and wetting cycle system; a reliable and predictable database should also be developed to investigate the work Changes, such as ink coverage, paper inventory, and standard weight and degree of tension required. Standard working adjustment curves can also be preset according to requirements.
Three main aspects to consider

Registration, color, and ink issues are the three main factors that waste printing preparation.

The automation of the printing control process is an excellent solution. For example, Berlin Industries uses a closed color circulation control system with a registration control system during the printing process. The closed color circulation control system improves the speed, which can help the printing machine to quickly reach the fixed speed through its own adjustment. This reduces the waste of paper and time by half. A large number of printing companies—regardless of size—do not control their inks at all. In fact, in the normal process, each batch of printed matter must be analyzed for ink printing. This requires the operator to understand the question of what is gray balance and how to use the density meter. If we are only printing in the traditional way, that is, judging the color through the eyes-then it will cause instability in the production process.

Of course, the human factor cannot be ignored. For example, the printing operator cannot be color blind.

For a web printing machine, if an automatic folding device is provided, the operator can only fold the printed product according to the product format in a short time.

The full automation of the entire operation process allows the operator to perform printing of various formats with a single key control.

Leverage advanced technology

A large number of control devices are added to the printing machine, which can reduce the printing preparation time. For example: automatic and semi-automatic plate setting device, color and color registration system and CIP3 preset system. In this way, the operator's main time is concentrated on the preparation process before printing.

In the pre-press process, adjust the printing content to suit the needs of printing. If a company has very good pre-press production equipment, but the jobs they produce are not suitable for the requirements of the printing process, problems will occur in the printing process. . Therefore, the pre-press production process must consider the printing process.

Regularly evaluate the work of employees

If the operator does something wrong, there is no need to blame them. You can post their finished products regularly to compare who is the best. Everyone knows that when a person does something well, there are times when it does something bad. We can say that we only track when it is good, and believe that no one wants to fall behind.
Provide employees with practical training opportunities during apprenticeship

Currently, operators rarely learn much during apprenticeship. For example, a new operator needs to learn to remove rollers, change plates and set ink fountains, and be able to operate the machine after three months.

Eliminates the need to wear paper

The threading process can reduce the printing preparation time. In each printing preparation, threading paper occupies about 10 to 15 minutes, including the time to find fasteners and the right hand tool to use when threading. It is recommended to use low-cost solutions such as dowels, clips, hinges, magnets, etc. to solve the problem of threading.

Help operators increase speed

Because the speed of current presses is close to 3000 feet / minute, the operator must adapt to it. When fast printing presses appear in enterprises with low production efficiency, they will find that the printing presses can not reach such a running speed, so they must strengthen management to increase the speed. Once you do this, you will find that the speed of other machines has also increased. Regardless of whether the machine is old or new, the preparation time will average over the entire production process. Whether it is running at 3000 ft / min or 1000 ft / min, every job must be stopped after printing-unless the cylinder has an automatic erasable function. If the staff knows how to prepare for printing, it can improve work efficiency.

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