Seven Innovative Technologies of Gravure Printing Machines
Fully Automatic Up and Down Rolling Technology for Gravure Printing Machines
In the production process, the fully automatic up and down rolling technology, through precise measurement and detection, automatically lifts rolls of different diameters and widths to the clamping position. The lifting device then automatically moves the finished roll out of the equipment position, while detecting the weight of raw materials and finished products during the lifting process. This technology seamlessly integrates with production management, replacing manual handling methods. It not only resolves the bottleneck where auxiliary functions cannot meet the normal efficiency of gravure printing machines but also significantly improves production efficiency, reducing the labor intensity of operators.
Fully Automatic Cutting Technology for Gravure Printing Machines
With fully automatic cutting technology, the entire cutting process requires placing the material roll on the feeding rack. The subsequent cutting process does not require manual intervention and can complete the entire cutting action. For example, with a BOPP film thickness of 0.018mm, fully automatic cutting can control the residual length of the material roll to within 10m. The application of fully automatic cutting technology in gravure printing machine equipment reduces dependence on operators and enhances work efficiency.
Intelligent Pre-Register Technology for Gravure Printing Machines
The application of intelligent pre-register technology mainly reduces the manual steps of operators using rulers for pre-registering in the early stage of the plate making process. It directly utilizes the corresponding relationship between the key slots on the plate roller and the registration marks on the plate surface. Through the automatic confirmation of the mechanical zero position of the plate roller, the initial pre-registering process is achieved. After completing the initial pre-registering process, the system automatically rotates the phase of the plate roller to the position where automatic pre-registering can be achieved based on the calculation of inter-color material length, automatically realizing the pre-registering function.
Semi-Enclosed Ink Trough with Lower Inking Roller for Gravure Printing Machines
The main feature of gravure printing machines is the effective prevention of ink splattering during high-speed operation. The semi-enclosed ink trough can reduce the volatilization of organic solvents, ensuring the stability of ink during high-speed printing. The amount of ink circulated has been reduced from the original 18L to around 9.8L. Maintaining a gap of 1-1.5mm between the lower inking roller and the plate roller ensures effective transfer of ink to the cells of the plate roller during the rolling process, achieving better reproduction of fine dot adjustments.
Intelligent Data Management System for Gravure Printing Machines
The main function of the intelligent data platform for gravure printing machines is to read the operating parameters and status of the selected machine control system on-site. It achieves necessary monitoring and parameter backup storage. The on-site intelligent data platform can accept process parameters and related order requirements issued by the remote intelligent data platform and authorize whether to transfer the process parameters issued by the remote intelligent data platform to the control system HMI, etc.
Digitalized Tension for Gravure Printing Machines
Digitalized tension replaces manually set pressure with direct setting of the required tension value through the human-machine interface. The tension values for each section of the equipment are expressed digitally and accurately in the human-machine interface. This not only reduces the dependence on operators during the production process but also enhances the intelligence of equipment operation.
Energy-Saving Technology with Hot Air for Gravure Printing Machines
Currently, three main energy-saving technologies are applied to gravure printing machines: heat pump heating technology, heat pipe technology, and a fully automatic hot air circulation system with LEL control.
Heat pump heating technology: Heat pumps are much more efficient than electric heating. Heat pumps used in gravure printing machines are generally air-source heat pumps, with actual tests showing energy savings of 60% to 70%.
Heat pipe technology: The hot air system using heat pipe technology enters the oven during operation, exits through the air outlet, and has a secondary air return device at the air outlet. Part of the outgoing air participates in secondary heat energy circulation for direct use, and the remaining part of the outgoing air is discharged as a safety exhaust system. The part of the hot air used as safety exhaust utilizes a heat pipe heat exchanger for efficient recovery and reuse of the remaining heat.
Fully automatic hot air circulation system with LEL control: Using a fully automatic hot air circulation system with LEL control achieves the following effects: under the premise of meeting the minimum explosion limit (LEL) and not exceeding the residual solvent limit, it maximally utilizes secondary air return, saving about 45% of energy and reducing emissions by 30% to 50%. The corresponding reduction in exhaust volume can significantly reduce investment in exhaust gas treatment for future emission bans, by 30% to 40%.