Current situation of the production process of the

2022-09-22
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According to the requirements of ISO9001 quality management system, in order to standardize the operation of each process in the production process, ensure the normal operation of production and ensure product quality, it is necessary for printing enterprises to formulate operation instructions applicable to the control of each process in the whole process of the product, and each competent department shall supervise the operation of each process, modify and improve the instructions, and each process shall be operated in strict accordance with the instructions and recorded

self-adhesive labels occupy an irreplaceable position in label products because of their bright colors, eye-catching contents, convenient pasting, good weather resistance and other characteristics. Large quantities of large, medium and small self-adhesive stickers are needed in so many fields, from instruction labels of all kinds of equipment, color stripes on motorcycles and automobile bodies, to large logo stickers on engineering machinery bodies. This paper will describe the specific operation and key points of each process in detail

I. blanking procedure

the blanking personnel shall receive the specified self-adhesive material from the raw material warehouse according to the blanking notice issued by the production department, check its model, and fill in the delivery note

when cutting materials, it should be based on the roll size (such as 1 m × 200 m), and correctly calculate the cutting size to ensure the full utilization of materials. During the cutting process, the appearance of raw materials is strictly checked according to the quality inspection standards, and the cutting error is controlled within 0.1 mm, and the edge removal size is controlled within 10 mm

when the sheet is broken, the material shall be cut in strict accordance with the material specification and quantity required by the material notice. If there are special requirements for the size of the backing paper on the drawing, the size error should be controlled within ± 0.2 mm, the manual breaking error of other products should be controlled within ± 1 mm, and the machine breaking should be controlled within the error range of the equipment

after the quantity of the cut self-adhesive material is confirmed to be correct, the name, quantity, size and material batch number of the product to be cut shall be marked with a film covered paper strip, which shall be attached to the positioning material of the whole batch of materials

the team leader of the blanking process is responsible for filling the material batch number in the "material batch number" column of the production voucher for the traceability of quality problems

II. Plate making and inking procedures

plate making personnel are responsible for signing in the negatives and color samples provided by the design department, and checking the quality of negatives, including the number of negatives, the identification content of negatives, the false and real degree of words, lines, points, the density of points, the registration degree between color separations, etc. If the negative is wrong, the repair sheet or rework sheet shall be filled in and returned to the design department together with the negative. For qualified negatives, the plate maker and the designer shall jointly sign and hand over on the negatives receiving sheet; The negatives that pass the inspection shall be kept clean, classified and stored in a special negatives bag. The cover of the bag shall be marked, including product name, number of negatives, packaging date, lending and return records, etc

the plate maker selects the appropriate mesh and size of wire and frame for stretching according to the fineness of the product. The tension is generally controlled at 6 ~ 8 kg/cm2. The plate can be removed from the stretching machine after being placed for at least 12 hours after brushing, and then the stretching time and tension value are marked on the edge of the easy-to-use version. Before printing, seal all sides with sealing tape and place it for 3 ~ 4 days (at least 24 hours). Before scraping, degrease and roughen the new version, then pour the photosensitizer into a glass in the dark room according to the photosensitive glue preparation instructions, add 80 ~ 100 ml of water, and stir it fully. After the photosensitizer is completely dissolved, filter it through a piece of 200 mesh silk, pour it into the latex, mix it well with bamboo chopsticks, cover it and place it in the shade, and use it after the bubbles disappear. Generally, 3 times of glue scraping is selected for products with fine lines and 2 times of glue scraping for products with dots. Put it flat in the oven after scraping, and place it at no more than 40 ℃ for 0.5 h until it is completely dried

before printing, wipe the front and back of the negative with cotton ball dipped in alcohol, repair the light transmission point, and the printing table should be clean and free of dirt. The selection of edition requires that the distance between the pattern and the border shall not be less than 15 cm. Under the safety light, adjust the angle of most lines and wires on the negative, and the point negative should be adjusted to a reasonable angle without moire. After vacuuming, the exposure time is selected according to different graphic contents and different light sources

after exposure, immerse the plate in the developing tank, and shake the plate repeatedly for many times until the pattern is clear and visible, and then flush it evenly with a high-pressure water gun. At this time, check the quality of the plate with light, and do a good job of self inspection. It is required that the edges of the pattern are free of sawtooth, clear and transparent, no deformity, no moire on the plate, no missing of small points, no paste of large points, etc. Dry the front and back of the plate with absorbent cotton, place it flat in the oven, and dry it thoroughly below 40 ℃. After repairing the missing version and checking the quality of the version, paste a label on the edge of the frame, indicating the product name, color, color sequence and printing time. Store it in the finished version storage area by classification, and record the relevant data in the version account, including the area code, layer number and all the contents of the above label. Account arrangement principle: according to the customer name, all products of each customer are arranged according to the size of the drawing number

each batch of supporting version must ensure the same tension and specification

according to the requirements of the product process standard, the long-term supply products are subject to the process card, and the new products are subject to the requirements of the drawing to receive the ink with corresponding performance. When receiving, check the following contents: whether the ink colors of the same model and different batch numbers are consistent; Whether the consistency of ink with the same model and different batch numbers is consistent. After confirmation, fill in the delivery form for use

when mixing ink, first judge the main color ink and auxiliary color ink, and mix them according to the approximate proportion. Note that the auxiliary color must be added to the main color, and record the proportion; After full mixing, scrape the sample with a scraper with the same mesh number and hardness as the official printing, compare it with the standard color sample after rapid drying, and adjust it until the color is consistent; After being signed and confirmed by the quality inspection personnel, the detailed proportion records of various inks shall be made in the ink color matching record book, and the signed and confirmed color samples shall be pasted

when the printer receives the ink, the ink mixing personnel uniformly distribute an appropriate amount of ink according to the blanking quantity and graphic area, and uniformly add diluent in the proportion of 10% - 15%. Record the amount of ink distributed by each printer; After printing, it is sent back to the ink room, and the ink mixing personnel are responsible for recycling the remaining ink, making records in the ink requisition registration form, and marking the outside of the oil cartridge

III. printing process

the printing staff first sell a small amount to the downstream. According to the requirements of the production summons and process card, they receive the corresponding version, ink and self-adhesive materials, and do a good job of mutual inspection, including: ① whether the received version and ink meet the requirements of the production pass or process card; ② Whether the quality of the printing plate meets the quality requirements for printing; ③ Check the surface quality of self-adhesive materials while counting. After checking, fix the plate and adjust the distance, and then use the self-adhesive positioning material for positioning. At this time, the position of the printed pattern should be determined in strict accordance with the positioning frame. The three positioning pieces are located at 1/3 of each positioning edge, and the size of the positioning piece is specified as 1 cm × 2 cm, mark the position of the positioning piece at the edge of the self-adhesive material when the original positioning is made

before the first piece printing, if the microcomputer function is strong, it can directly print the used master paper for printing. After the first piece of monochrome printing is completed, it must be confirmed by the quality inspection personnel, and the words "agree to print" must be signed on the color sample of the first piece of product and signed; During the formal printing, it is necessary to compare and check one by one. If any abnormality is found, appropriate adjustments should be made, such as adding thinner, adjusting the angle of the scraper, changing the ink, etc

products requiring fine quality can be printed only after the surface of self-adhesive material is wiped with an electrostatic brush, electrostatic rag or non-woven cloth dipped in alcohol. According to the printing quality inspection standard, take each printing machine as the preliminary self inspection unit, and strictly distinguish the qualified products and unqualified products during the printing process

when printing transparent self-adhesive materials, the vehicle color penetration test must be carried out, and the printing can only be carried out after passing the test

after printing, for the self-adhesive printed with Japanese Seiko ink, push the drying rack into the drying room, set the temperature at 45 ~ 50 ℃, bake for 20 ~ 30 minutes, and then push out the drying room to dry naturally; After the printing of other types of inks is completed, they can be folded and stacked after being naturally dried indoors for 24 hours, otherwise they must be placed vertically; For overprint with more than two colors, the interval of overprint should be controlled at more than 30 minutes

when collecting prints from the drying rack, ensure that the positioning edges are consistent without scratches and wrinkles; For unqualified products, it should be used on the bottom paper“ ×” Number is marked on the corresponding part; Use the laminating paper to distinguish the qualified products from the unqualified products, count their respective quantities, and fill in the production summons

IV. knife mold making and die cutting process

the design department shall make the knife mold line pattern of the final product according to the requirements of the drawing, and submit it to the knife mold maker. After checking it, paste the pattern on a 5 mm thick plastic plate, and use a sawing machine to saw the figure outline according to the knife mold line. The edges are required to be even and smooth

use a knife mold forming machine to make the daily output 0.45 mm × The 9.5 mm knife bar is embedded in the gap of the knife die line, and then manually press cut with self-adhesive ① unload some infrequently used software ② before applying the control software, be sure to end the operation of other software tangent, check the size of the tangent and whether the edge is smooth, and require that there is no gap and dislocation at the knife bar interface, which is inspected and confirmed by the quality inspection personnel, and fill in the mold confirmation report

after the knife template is made, stick it to the blade surface with foam adhesive to protect the knife blade from damage. Finally, mark the product name, production date and producer on the knife template and hand it over to the die cutting personnel

die cutting personnel first check the quality of the knife template, number it after confirmation, and record it in the knife template account in time. The principle is: all knife templates are arranged according to the name of the customer, and all knife templates of each customer are arranged according to the size of the drawing number, which makes it accurate and time-saving to find the knife template

when receiving semi-finished products from the printing process according to the production voucher, you must count the quantity, distinguish the qualified products from the unqualified products, and check whether the surface of the semi-finished products is scratched, whether the positioning edges are placed consistently, and do a good job of mutual inspection

find the knife template according to the production voucher and the knife template account, install it on the die-cutting machine, adjust the pressure according to the requirements of the product (half break or full break), the spacing from large to small, and determine the die-cutting location according to the original printing location

in the process of die cutting, self inspection shall be carried out in strict accordance with the die cutting quality inspection standard, with a proportion of 10%, and qualified products and unqualified products shall be distinguished; According to the counter, each die-cutting 100 sheets, separated by the bottom paper, and finally placed in the semi-finished product area, fill in the production voucher

put the used knife template back to its original place. If there is a problem, fill in the repair form in time, return it to the knife mold manufacturing process, and after each die cutting, indicate the die cutting date, die cutting quantity and knife template quality in the knife template account. For self-adhesive labels that need crystal glue, please continue with the following operations

v. in the inspection stage before dropping molding, the sorting personnel go to the die-cutting process to receive semi-finished products according to the production voucher. They need to count the quantity and distinguish between qualified products and unqualified products. Check the quality of die-cutting semi-finished products while discharging wastes according to the quality inspection standards, distinguish the qualified products and unqualified products after inspection, and mark them with laminating paper strips for the next process; If repair is required, fill in the repair form and return it to the relevant process

VI. dripping process

it is forbidden to drip plastic with unqualified products. Before plastic dripping operation, the workbench should be adjusted to make it level, and the semi-finished products should be pasted on the glass plate without bubbles and inaccurate pasting

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