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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 are 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 6 years, Teknek (UK) is committed to introducing and promoting the benefits of 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 Tenico's special polymer cleaning roller to clean the substrate. The cleaning roller removes dry, independent contaminants from the substrate and transfers them to Tenico ’s unique reverse-winding adhesive roll. When the sticker is full of contaminants, replace this layer of sticker, you can continue to clean without interrupting printing production. Technic's cleaning technology can remove contaminants as small as 2 microns on the substrate surface.
How to save?
The use of Tenico ’s 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 extensive practical experience, the installation of Tenico ’s cleaning system will reduce the possibility of solid particles by more than half.
Assuming that Tenico ’s cleaning system only prevents one stop / shift (the management will usually take more than 2 times), each stop for 20 minutes (minimum estimate), and generates about 100 meters of waste. The printing plant works 50 weeks a year , 5 days a week.
Calculation result of saving label raw materials:
1 printing machine saves raw materials every year = 100x5x50 = 25,000x0.345 = 8625 square meters
Over the past 6 years, Tenico has installed 1,200 cleaning machines in the European label printing industry.
Conservative calculations:
Obviously, Tenico has saved about 36 million square meters of raw materials for the label printing industry and reduced downtime by 350,000 hours in the past 6 years. These data are very conservative calculations, and do not include the cost of ink, electricity, labor, etc. related to printing production. The cleanliness of contact substrates promoted by Technic Corporation has helped enterprises to save resources and reduce waste significantly, and changed the label printing industry's understanding of handling raw material contaminants.
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