In recent years, with the rising cost of manpower, raw and auxiliary materials, and the difficulty of recruiting workers and people, it is becoming more and more challenging. All walks of life are facing enormous challenges. The printing industry is no exception. It has become a common consensus for everyone to use automation, information technology and intelligent means to improve the production process and seek industrial upgrading.
In order to promote the process of “machine generation†and “smart printing factoryâ€, our company has been introducing automation equipment for many years, replacing equipment by equipment and improving equipment automation, which has significantly improved the company's production efficiency and product quality. In the forefront of the industry in the introduction of new equipment and technological innovation.
In the die-cutting process, our company introduced a full-disposal die-cutting machine in 2015 and 2016. In the application process, through the continuous optimization of equipment and technology, the advantages of the full-clear die-cutting technology were fully utilized. Improve the production efficiency, production capacity and product quality of our company's die-cutting process.
In this paper, the author will analyze the existing problems, advantages and optimization process of the application of all-disposal die-cutting technology in the field of drug packaging, hoping to learn from and help the peers.
01 introduction background
In the first half of 2015, our company's business increased greatly. Compared with the same period of last year, the die-cutting output increased by 20%, far exceeding the existing die-cutting capacity, so it could not be delivered in time, and the production pressure was huge. At that time, our company had 7 die-cutting machines, but it generally entered the “agingâ€. Among them, 5 die-cutting machines that have been in operation for more than 10 years (two have been in operation for 15 years), the equipment accuracy and condition are poor, and it is no longer possible. Production in the peak season requires the purchase of new equipment to increase production capacity. In addition, due to the labor intensity of the stripping process, there is a difficulty in recruiting workers and making it difficult for people to stay. When the production of waste in the peak season is insufficient, all non-production personnel turn to the workshop to clear the waste three days a week, which has adversely affected normal production and operation. It is urgent to increase the die-cutting equipment and improve the automation of the equipment.
The all-clearing die-cutting machine can use the all-cleaning station to remove the waste edge of the paper, and collect the intact box, eliminating the original manual tearing and scrapping process, which is not only efficient but also caused by manual waste. The tearing, tearing, etc. are avoided and the quality of the product is improved. The introduction of the full-clearing die-cutting machine not only improves the die-cutting capacity, eases the pressure of manual waste-cutting, but also meets the development ideas of the “machine-generation†plan and the “smart printing factory†construction of our company. To this end, our company, as the first person to eat crabs in the field of drug package printing, took the lead in introducing a full-clearing die-cutting machine, and since then it has moved to the era of all-discarding and die-cutting after drug packaging.
02 Existing problems and advantages
As we all know, the full-disposal die-cutting machine has been the first in the field of cigarette packages since its inception. Many die-cutting equipment manufacturers have tailored them to meet the requirements of “exquisite appearance, complicated process and strict quality controlâ€. A complete decontamination process plan, including the design of the equipment itself, the technical parameters of the box, etc. It can be said that in China, the full-clearing die-cutting machine is born for cigarette packets.
In recent years, due to the soaring labor costs and other factors, drug package printing companies have begun to pay attention to the full-clearing die-cutting machine. Although the application of the whole-cleaning die-cutting machine in the field of cigarette packets is very mature and stable, the characteristics of cigarette packets and drug packs are different. Whether it can be well integrated into the production of pharmaceutical packages, many drug package printing companies are waiting to see. Then, in what areas does the application of the complete stripping die-cutting technology in the field of drug packs “accepted�
1. The package order is small
In general, cigarette pack orders are large in volume, and a single order is usually produced continuously for several days or even longer. The large-volume products can fully utilize the advantages of the full-clearing die-cutting machine. The order of the drug packs is small. In our company, for example, there are nearly a thousand orders per month. The production volume of each order is generally 15,000 to 17,000 sheets, and each shift needs to be replaced with 3 to 4 orders. Orders are far from each other, and frequent replacement orders greatly reduce the efficiency of the full-clearing die-cutting machine.
2. There are many types of drug packs
As we all know, the types of cigarette packs are basically the same, but the types of packs are various. Some of them look basically the same, but the actual measurement is 1~2mm. Therefore, under normal circumstances, the number of die-cut editions of a large-scale pharmaceutical package printing enterprise is 1000-2000 pieces or more.
For the full-clearing die-cutting machine, in addition to the high price of the equipment itself, the biggest cost investment is the box-splitting device. The price of each box-boxing device is tens of thousands of yuan. It is impossible to prepare a set of boxers for each product. Only some products with large orders can be selected for full stripping. Even if it is used, 40 to 50 sets of 40 parts should be prepared for the use of a full-cleaning die-cutting machine. Box splitter.
Therefore, due to the wide variety and non-standard types of drug packs, it not only reduces production efficiency, increases production costs, but more importantly, it is also a serious waste of social resources.
3. The asymmetric side of the waste paper
Figure 1 shows the side of a conventional cigarette packet waste paper, and Figure 2 shows the side of a conventional package waste paper. Through the comparison of the two pictures, we can find that the waste paper side of the drug pack is much more complicated than the waste paper side of the cigarette pack. Due to the irregularity and complexity of the waste paper, the production of the whole waste paper-cutting machine is seriously affected. effectiveness.
However, due to the different way of the package and the cigarette pack, there is still a difference in the process of the whole waste. In comparison, it is easier to clear the package. The whole process of the cigarette package is: first die-cutting, then clear the hole position and the trailing edge in the semi-cleaning unit (as shown in Fig. 3), and finally clear the box in the full-cleaning unit. The layout of most of the medicine packs is shown in Figure 4. All the waste paper edges are connected together except for the box. The complete stripping process of the medicine package of this joint type can be after die cutting. The box is cleared directly in the full-cleaning unit, eliminating the intermediate half-disposal link. Of course, according to the different layout methods, the complete waste disposal process of some drug packs will be the same as the cigarette pack.
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