Newspaper printing is a race against time, and it has a strong timeliness. Paper breakage has become the main factor affecting timeliness, making the printing house miserable. At the same time, the second start-up caused by the paper break wasted paper and other printing consumables, and engulfed the meager profits of the printing house.
How to reduce paper breakage or continuous paper has become a problem that needs to be solved urgently.
The author analyzes this phenomenon based on the usage of our factory Universal 70 over the past six years.
1. The hazard of paper break
1. Affect the publication timeliness of newspapers. Statistics have been made, such as cutting one piece of paper at a time, it takes about l2 minutes from cutting the paper to restarting the machine. If the paper breaks cause secondary hazards, such as crushing the rubber blanket or the paper winding roller, the delay will be even longer. Long. In the distribution market where every second counts, if there is a aging accident, it will affect the market share of newspapers. As far as printing companies are concerned, frequent aging accidents will affect their credibility and seriously lead to the loss of customers.
2. Affect the profit of printing factory. Take our four tower printed 32-page evening papers as an example. When the paper is cut off once, it will generate more than 1,200 scraps in the second boot, which is about 5,000 pairs of openings. It will cause more than one hundred kilograms of paper waste at a time, calculated at 5500 yuan / ton. It is more than 600, which is not counting consumables such as ink and fountain solution. In addition, the printing factory, the editorial department, and the distribution company all have time-limited reward and punishment contracts. If the printing factory is delayed, a fine will be paid, and the loss will be even greater.
3. Secondary hazards caused by broken paper. Interruption of paper at high speeds often crushes the blanket. It takes 15 minutes to replace a blanket, and a blanket of more than 1,000 yuan can be seen as a hazard. In addition, the high-speed paper-breaking machine has no buffer, causing a hard landing, which seriously affects the service life of the machine.
2. Causes of paper breaks and solutions
(1) Paper reason
Needless to say, paper quality problems are a very important cause of paper breaks. Common paper diseases are: there are holes in the paper, and the paper is broken when the paper breaks detection; there is adhesion between the upper and lower layers of the paper, the paper is torn during printing, and the paper is broken; the paper has broken edges, overcast, not Timely detection and processing, thus breaking the paper; paper rolls produced in the production, transportation, storage and other links are too eccentric and easy to print the paper break; the joints in the paper roll are easy to break; the paper is not easy to pull, it is also easy to produce paper breaks
Solution: â‘ Strengthen the communication with the paper mill, keep the paper pattern, and let the paper mill strengthen the quality control. â‘¡ Paper storage and transportation should be standardized to avoid damage to the paper. â‘¢ Replace the paper in question when printing.
(2) Reasons for printing equipment
1. The paper feed section is malfunctioning. Common failures caused by electrical faults, such as abnormal paper breaks, disordered paper playing, paper rolls not receiving paper, and paper rolls running out, etc .; mechanical failures are mainly brake pad problems. At the beginning of our 70 machine, due to brake pad material problems, The tension is too small when receiving the paper, so that the paper breaks many times.
Solution: â‘ Operators should strictly follow the instructions. â‘¡If there is a program failure, power off and reset. â‘¢Please check and deal with the electrical staff. â‘£Brake pads must ensure quality and be adjusted regularly.
2. Infeed failure. Common failures include shaftless transmission failure, governor failure, and paper breakage; communication failure, paper breakage; paper feed roller rubber roll, rubber breakage, etc.
Solution: â‘ Check the running status of the paper feed roller driver, and find the problem and deal with it in time. â‘¡Check the communication optical cable. â‘¢ Periodically check and adjust the pressure of the paper feed roller rubber roller, and find that it is excessively worn, and replace it in time.
3. The printing department is malfunctioning. Common faults are: â‘ a paper motor drive failure caused by out-of-synchronization caused a paper break; â‘¡ communication failure caused by a shaftless transmission failure caused a paper break; â‘¢ water spray bar failure caused the machine to spray water in a non-printing state, and the printing cylinder was too wet during printing. The paper breaks when pressed together; we have encountered this situation many times. â‘£Blank breaks when the blanket comes off during printing.
Solution: â‘ Check the running status of the drive and deal with any problems found in time. â‘¡Check the communication optical cable. â‘¢Replace the water spray bar, such failures will be analyzed. If the printing plate is dry on the machine, and the paper is broken after the pressure is pressed, and there is a watermark on the paper, then you should consider checking the water spray bar. â‘£Check the rubber cloth before starting, especially the one with the tight edge and easy to come off. This is a quality problem and it is best not to use it.
4. The paper roll is too thick and the paper is easy to break. Long-term printing, such as the ink roller is too thick, it is easy to break the paper, especially when receiving the paper, generally, it can be wiped once a day.
5. The drive of the pull roller drive is faulty. The paper pulling roller is an important part of the tension system. We have encountered a situation where the drive has overheated to prevent the paper from breaking. It is often because all the paper paths are broken and the time is serious. After inspection, the cooling fan of the driver is faulty, and the fault is eliminated after replacement. Note: The refrigeration equipment in the electrical cabinet should be checked regularly, and the filter should be cleaned regularly to avoid overheating protection of the drive.
6. Paper breakage caused by instantaneous power failure. Because the machine is a shaftless drive, the momentary power failure will cause all the paper in the printing to break, and it is easy to burn out electrical components, which is a huge hazard. Therefore, it is necessary to coordinate with the power supply department. It is also necessary to add ups backup power. There was a momentary power failure during night shift production, the shaft drive equipment just stopped and then turned on again, and all the paper paths of the 70 machine were completely broken, and a relay was broken, the time was serious, and the 75 machine of the UPS was installed. No downtime, no impact on production.
(3) Paper break caused by human error
To be honest, the situation of paper breakage caused by improper operation of the operator or weak sense of responsibility also occurs from time to time. The common ones are:
1. The common problems of the paper feeder when handling paper are: â‘ The black label is not in the correct position when processing the paper, causing a signal disturbance during paper pick-up, which is easy to run out of the paper roll; â‘¡ The tape is not attached well, causing the paper to break when receiving the paper, and often It is accompanied by the case of crushing the blanket; â‘¢ The top cone is not fastened after loading the paper (non-automatic paper holder), the tension is not enough when starting the machine, and it is easy to cause the edge to break the paper.
2. The common problems of layout personnel are: ①The water trace on the plate is not dried in time after the edition, resulting in water in the roller, and the paper is broken when the pressure is turned on; ② Ink is accidentally added to the ink roller when adding ink, instantaneously Too much ink, sticking to the broken paper; ③ The electrical eye of the broken paper detection was not wiped in time after printing a printed product, which caused the paper knife to hit the paper when starting up; ④ After printing the narrow-width paper, change the larger-size paper to print When the blanket is not cleaned, the paper will stick when the machine is turned on; ⑤ The tension wheel in the middle of the printing section is pressed too tightly. When the paper is turned on, the paper is cut from the middle to break the paper.
3. The tension setting is not suitable when printing on multiple paper paths, the tension does not match, some paper has a large force, and the tension is small, and the paper with a small tension runs left and right to cause a paper break.
The solution is to â‘ do a good job of employee training, let the operators understand and master their respective job essentials, and master proficiency; â‘¡ strengthen the system constraints, let employees do their work carefully, do a good job, and strengthen their sense of responsibility.
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