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In the process of label production, micro-pollutants in the air are one of the culprits causing waste (waste and downtime). The printing house currently has no solution to this problem. The printing house believed that the material supplier Film was not clean, and the supplier accused the printing house of poor working environment. Both sides are in a dilemma.
Label materials are very sensitive to static electricity accumulation. The accumulated static electricity is like a magnet attracting pollutants around the surface of the raw material. These contaminants may come from packaging, clothing fibers, hair, cutting dust, ink stains, metal dust, etc., which can cause printing problems.
There are two main reasons for pollutants in the air to cause waste in flexographic printing plants:
1. Contaminants transferred from the substrate to the impression cylinder
This situation can cause image errors in printed products. The general treatment method is to stop the machine and clean all the impression cylinders. The cleaning process generally requires 1 to 2 hours of downtime, resulting in 50/100 meters of waste.
2. Contaminants are transferred directly from the substrate to the plate roller
This situation causes a solid particle on the plate roller. If the UV ink is very thin and sticky, this situation will be worse, a small dust will stick to the plate stick to form a repeatable error. The operator must use a soft brush or rag to clean the running plate stick. First, this approach is not safe. In addition, if it cannot be cleared, the operator must stop, clean all the plate rollers, re-register the machine, and check the print and quality again. This process will produce 50 meters of waste material, lost production time, and more importantly, the problem has not been fundamentally solved.
Solution-Clean substrate
It sounds very simple and obvious, but what do you use to clean the substrate?
In the past few years, the benefits of promoting contact cleaning technology for the label printing industry. This innovative cleaning method was originally developed for the electronics industry, and is now selected and used by major printing equipment manufacturers and label printing companies in the world and integrated into their production systems.
Use the polymer cleaning roller of the dust and static cleaning system to clean the substrate. The cleaning roller removes the dry, independent contaminants on the substrate and transfers it to the unique reverse-winding sticky paper roll of the Thai dust removal electrostatic cleaning system. When the sticker is full of contaminants, replace this layer of sticker, you can continue to clean without interrupting printing production. The cleaning technology of the dust and static cleaning system can remove contaminants as small as 2 microns on the surface of the substrate.
How to save?
The use of dust and electrostatic cleaning systems in label printing production results in reduced waste and downtime.
For example, a 4-color 345 mm flexo printing machine runs different printing materials. Under normal circumstances, 8 hours of shifts will have 4 solid particles on the plate roller. Based on a large number of practical examples, the dust and static cleaning system will reduce the possibility of generating solid particles by more than half.
Assuming that the dust and electrostatic cleaning system only prevents one shutdown / per shift (the management will usually be more than 2 times), each shutdown for 20 minutes (minimum estimate) produces approximately 100 meters of waste, and the printing plant works 50 weeks a year, each 5 days a week.
Calculation result of saving label raw materials:
1 printing machine saves raw materials every year = 100 × 5 × 50 = 25000
25000 × 0.345 = 8625 (square meters)
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