The printing methods of corrugated boxes have undergone major changes in recent years. The old low-speed, low-quality, and inefficient printing methods, such as long ink road offset printing, letterpress printing, and silk printing, have experienced the elimination of lead printing like book and newspaper printing Like the revolution of the United States, entered a situation dominated by flexo printing.
The rapid change of corrugated box printing methods is not the topic of this article. This article mainly talks about the corrugated box printing methods, the actual problems that everyone is more concerned about and what to solve, and their application prospects. I have experienced this change, I know a little about the printing technology changes, and talk about the development of the domestic market economy and enterprises.
With the development of China's economy and the continuous improvement of people's cultural and living standards, new requirements are placed on the packaging of goods. Commodity packaging requires attention to humanization and functionalization; commodity packaging requires the promotion of the attributes of the commodity, reflects the value and information of the commodity, has the function of protecting and preserving the commodity, is environmentally friendly, meets the needs of marketing, marketing, and competition; and requires the packaging to be beautifully printed , Creative novelty, beautiful shape, can attract the attention of consumers. The corrugated box printing industry has followed these requirements and rules. Nowadays, it has developed from simple transportation packaging to packaging that meets transportation, sales and functionalization, from flat boxes to special-shaped boxes and functional boxes (convenient portable, ventilated, isolated, Moisture proof, etc.), from A, C type corrugations to A, C, B, E, F, M type corrugations, from printing monochromatic text, lines to multi-color maps, from heavy boxes to light boxes.
In order to improve the plate-making and printing quality of packaging products, corrugated box printers use advanced technologies at home and abroad in various printing methods such as flexo printing, offset printing, gravure printing, and inkjet printing. It is rare for a packaging product to use multiple printing methods and technologies. Of course, it is impossible to use so many printing methods at the same time. It is worth exploring which printing method is the best and which printing method is the best for packaging products.
Various printing methods are used for post-printing and pre-printing of corrugated boxes, which can be divided into two categories:
Post-printing of corrugated cardboard box: directly print on the face paper of corrugated paper (three-layer or five-layer), there are three ways:
â‘´Corrugated cardboard box flexo printing slotting machine (die cutting or box making online production line);
⑵ Lithography (three-layer paper);
⑶ computer inkjet.
Corrugated Carton pre-printing: first print on facial paper, and then mount (replicate) the printed facial paper with corrugated paper (including backing paper) and then make the box. There are six more options:
(1) Sheet-fed offset printing, and then mounted with corrugated paper;
⑵Flexible printing of web paper (model: satellite type), then re-sticking with corrugated production line to produce corrugated cardboard
⑶Roll paper flexographic printing (model: unit type, stacked type), online cut into single sheets, and then mounted with corrugated;
â‘·Rotary paper gravure printing, reattach to corrugated production line, and then make corrugated paper;
⑸Rotary paper gravure printing, off-machine cut into single sheets, and then mounted with corrugated;
⑹Rolled plastic gravure printing, and then mounted with a single corrugated paper.
The following analyzes several printing methods.
1. Post-printing corrugated box flexo printing slotting machine method
This printing method was introduced in China in the early 1980s (commonly known as watermarking machine), but its development is slow. The main reason is that corrugated boxes are used as transport packaging and corrugated paper is still printed in an intensive and low-cost way. Using screen printing, the ink layer is thick, the ink is easy to wear when being transported, and it will pollute fingers and clothes. Only after environmental protection problems occur in export packaging, people gradually pay attention to environmental protection.
In fact, the "watermark" method has many advantages:
(1) Using flexible printing plates, not only can copy text, lines, solid floor, but also can copy fine screen version, the plate making speed is faster than the hand-engraved rubber version;
⑵Can form a linkage production line with other processes;
(3) Flexible printing plates can be compressed and deformed. For flat printing and gravure printing, the thickness of the printing base material must be consistent, the surface is smooth and flat, and corrugated paper is generally not available. It is precisely because the flexible plate can be compressed and deformed. A little error has little effect on quality, and the printing plate can also print out pictures and text;
â‘·It belongs to high-speed, high-quality and efficient printing methods;
⑸ Water-based ink can be applied, which is convenient and environmentally friendly;
⑹The structure of the flexo printing machine is relatively simple, suitable for large-size Carton requirements.
Corrugated carton flexo printing slotting machine, the printing width reaches 1.6 meters, 2 meters, 2.5 meters, 3 meters, and even more than 3 meters. There are three types of such machines, which can meet different enterprise and production requirements:
(1) Flexo printing-slotting machine: This kind of equipment is widely used at present, suitable for flat box, also for printing color pictures and off-machine die cutting. For special-shaped boxes and function boxes, 1 to 5 color groups can be selected according to needs;
⑵Flexo printing-slotting-die cutting machine: the current application is increasing year by year, suitable for special-shaped boxes and functional boxes, and 4 to 6 color groups can be selected according to needs;
(3) Flexographic printing-slotting-gumming-folding box making-bundling production line: corrugated cardboard goes in the assembly line, the carton comes out, and it is directly loaded on the truck and shipped out.
Corrugated boxes are printed on flexo plates, which account for 95% in the United States (some sources say 98%), of which post-printing accounts for about 70%. At present, it is estimated that domestic post-india accounted for 58%.
Why does domestic lithography infiltrate corrugated boxes? The author analyzes that there are three reasons:
(1) Corrugated cardboard boxes in the United States are not pre-printed with sheet-fed sheets. The national situation is that the US private economy has developed for a long time, and there are not many printed copies in small batches;
⑵Domestic corrugated carton printing used to be mostly text, lines, and field. There are almost no dots, let alone multi-color overprinting of color pictures. Multi-color overprinted color pictures were only launched in the last seven or eight years. Although the number of printing plates is not high, the printing plates have a large area. As printing experts know, the higher the number of printing plate lines, the larger the plate area, the greater the difficulty of printing. The printing area of ​​some single corrugated paper in China reaches double full sheets or complete sheets, the application time is short, and the technology cannot keep up;
(3) Conceptually, domestic requirements for packaging and printing quality are higher than foreign ones, and foreign requirements are simple and practical. Therefore, the quality of flexographic printing in the United States meets the requirements of corrugated boxes, while domestically it must rely on lithography.
Corrugated carton flexographic post-printing technology is now widely used in China, and the prospects are optimistic. The advantages of post-printing are: inline production, high efficiency, plus the use of water-based inks for flexo printing, environmental protection, light pressure, low printing base material requirements, less bad films, and low equipment prices. Leading role. Now some concepts are gradually changing, such as over-packaging, compliance with environmental protection requirements, and excessive pursuit of print quality.
The key to post-printing is to improve the quality of the original and flexo printing. The number of printed lines of corrugated cardboard boxes abroad is not high (60 to 100 lines / inch), and the image looks bright, the vision is good, the three-dimensional sense is very strong, and the colors are also rich and bright. The key is the original. There are gaps in this area in China.
There are many varieties of corrugated boxes, and the quality requirements are different. The printed products are single-color and double-color, there are characters and lines, and there are on-site and color pictures. Enterprises should position themselves well, do not participate in vicious competition, develop linkage production lines, pay close attention to quality, and communicate more with plate-making units.
In principle, the ceramic anilox roller can be used to print color images. Generally, 40 to 80 lines / inch is used for printed products, and 80 to 110 lines / inch is used for fine products. Printing Mandarin should not be used. ".
Recently, I reviewed a bid of a certain unit. The introduced flexo printing slotting machine is very advanced, but unfortunately there is no requirement for the thickness of the printing plate. The thickness of a good device plate should be 2.84 mm, not 3.94 mm. The development trend of flexographic plate materials is that the thickness should be thin and the hardness should be high. The purpose is to reduce the deformation of the printing plate and restore the dots well. Conditional units should use thin printing plates. Only when the color pictures are printed can we increase our competitiveness and occupy the market. [next]
2. Preprinted sheet-fed offset printing method
The characteristic of pre-printing is good printing quality. If it is lithographic printing, it can be printed to 175 lines / inch. Domestic lithographic printing is used for pre-printing, which is a large number. It is estimated that it currently accounts for 30% of this field. There will also be a market for a long period of time, but eventually it will go downhill.
Reasons for preprinting in domestic lithography:
(1) The private economy is underdeveloped and the accumulation of capital is insufficient, resulting in low commodity output or low working capital, so packaging products are printed in small batches;
⑵Commodity promotion needs to beautify through packaging, and the quality of lithographic printing is very good. Although the cost is higher than that of post-printing, for high value-added products such as food, gifts, toys, electrical appliances and other products, the proportion of cost is not large;
(3) The current plate-making costs of post-flexo printing are relatively high, and the quality cannot keep up. Therefore, some enterprises value the sheet-fed lithographic pre-printing market, and have purchased a very large-scale (above 1.4 meters) lithographic printing machine, laminating machine, and die cutting machine.
Sheet-fed lithographic printing is followed by mounting with corrugated paper, die-cutting, and box-making. This method is relatively expensive and restricts development. If the quality of the flexographic printing is further improved and the batch size is increased, the flexographic printing method is more suitable.
3. Pre-printed web flexo printing method
Roll paper flexo pre-printing method, the number of printing plate lines is mostly 120-150 lines / inch, and the printing quality is good. This method accounts for about 25% in the United States, and it is currently estimated to account for about 3% in the country. The pre-printing method and box-making process have been successfully explored and put into production in Sichuan Deyang Daily Printing Factory in 2002. Xi'an Aerospace Huayang Printing and Packaging Equipment Co., Ltd. manufactured this equipment in 2007—a satellite-based flexo printing machine, and Has been mass produced. This creates favorable conditions for web preprinting and is expected to develop in recent years.
This technology is restricted by two aspects:
â‘ The amount of printing needs to be very large (currently mainly used for beer and milk carton packaging printing);
â‘¡Requires good printing quality (otherwise it can be replaced by flexible printing). There will be a certain demand in the domestic market, and it is estimated that it will develop to account for 8% to 10% of this field.
4. Pre-printed roll flexographic printing method
As mentioned above (roll-to-roll), the pre-printing requirements are large-volume orders. If it is not a large-volume order, what can you do? You can use roll paper to flexo it, cut it into a single sheet, and then mount it. This method has lower equipment requirements, and can be printed on a unit-type or laminated flexo printing machine. The quality is better than that of post-printing. It is suitable for large-width orders, such as carton boxes of over 1.2 meters in size. If the lithographic printing method is used to exceed the specifications of a full-page printing press, the offset printing price that exceeds the full-sheet specification is very high, the printing cost increases, and the flexographic printing method is much lower in price. This technology currently has an upward trend.
5. Post-printing lithography
There is demand in the market, and people will always find ways to meet new demands. Lithography requires uniform thickness of the substrate, good flatness, smooth surface, if it is rough corrugated, it cannot be printed directly on the lithographic printing machine, usually used fine corrugated (E, F, M type) and high quality weight slightly higher Corrugated paper made of paper, which meets the packaging and packaging requirements of high-end goods.
Figure 1 and Table 1 show the current status and future forecast of post-printing and pre-printing.
The pre-printing method of gravure printing technology once rose for a while, but now it gradually declines. In the initial stage of flexo printing, gravure roll pre-printing can print 150 lines / inch, of course, the quality is slightly better. A plastic film with a gravure color picture is mounted on the corrugated fruit box, which is shiny and beautiful. Later, this method was gradually replaced by single-sheet lithographic pre-printing. Web gravure preprinting is now gradually replaced by satellite flexo printing.
Computer inkjet printing color pictures are rarely used, mainly because the processing fee is too high, 50 yuan / square meter. Recently, a unit undertook an external order. The contract was about to expire and fined when it expired. The inkjet method had to be used to complete the task. Inkjet printing color pictures is suitable for a small number of urgent items and sample boxes.
The world is advancing and commodities are increasing. Packaging and printing are increasing by double digits every year, and the situation is very good. One person once said, "If there is no packaging, the world will not know what to do." Unpredictable changes in the market, companies must pay attention to the market, follow the market, go right, you can start business.
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