How does gravure achieve green environmental protection?


New technologies, new processes, new equipment and new materials in the gravure industry will develop rapidly in the direction of environmental protection, energy conservation, emission reduction, loss reduction, quality improvement and efficiency. In this context, a series of new technologies, such as non-benzene technology, loss control, high-efficiency drying equipment, and solvent recovery, have begun to be applied to the flexible packaging gravure industry.

Renovation and upgrading of equipment such as gravure printing

The largest material loss in the gravure production process is the waste generated by commissioning and overprinting. If the fine adjustment operation and process steps are closely linked, a stable and predictable waste value will be obtained. Domestic gravure equipment manufacturing enterprises adopt the latest technologies such as fast pre-registration and high-precision tension control, which cause cutting loss, equipment restart loss (already registered), exchange loss, re-starting previously stored order loss, and slowdown. Losses and the like have reached a fairly low level and are even better than the international advanced level in some respects.

Under the pressure of soft packaging products, domestic flexible packaging gravure companies have paid more and more attention to the material consumption indicators in the printing or compound equipment processing process (including normal roll change) in order to minimize the product cost. Therefore, material loss data has become an important consideration for equipment selected by flexible packaging gravure companies.

Today, advanced gravure press operation assistance time is greatly reduced. The upper plate and the inking integrated car realize the integrated operation of the upper plate, the running plate and the inking, and can clean the plate roller and the ink tank offline; through the fast inking system, the solvent is directly supplied into the ink disk from the solvent room, and the supply amount is directly Controlled by ink viscosity controller; sleeve press roller technology eliminates tooling replacement, labor intensity is reduced, replacement time is greatly shortened; rapid replacement of scraper technology enables rapid replacement of scraper; laser edge-to-edge system, safety chuck quick-clamping system realizes fast Up and down roll; fault display and alarm help maintenance personnel to quickly diagnose and repair; historical fault alarm indication can reduce the time for maintenance personnel to troubleshoot.

The energy consumed by the drying box in the gravure printing process accounts for a large proportion. The application of heat pump technology, waste heat recovery system and layered oven effectively reduces the consumption of heat energy. LEL-based fully automatic monitoring and drying system can prevent the risk of explosion and combustion of the drying system while saving energy and reducing emissions, and greatly reduce the cost of exhaust gas treatment.

Exhaust emission control

There are three main ways for gravure VOC emission control measures, namely source management, process management, and end management.

Source control reduces the amount of organic solvent used from the beginning of the printing process to achieve VOC reduction. The main measures are to promote low-VOC or non-VOC environmentally friendly inks, cleaning agents and other raw and auxiliary materials, such as the promotion of water-based inks, single solvent inks.

Process management is to achieve VOC reduction goals by improving drying efficiency and production site management during the printing process. The main measures are to carry out technological innovations on the printing press, so that the VOC air volume produced by the production is reduced, the concentration is increased, and the heat energy utilization is increased. For example, the LEL device is added for the equipment, the solvent evaporation at the workshop site is reduced, the ink tank is capped, and the clean production is promoted. , green printing certification, etc.

End treatment currently has two main directions, namely recovery and combustion treatment. The recovered volatile organic compounds can be directly or simply purified and returned to the process for reuse to reduce the consumption of raw materials, or for the production process with low quality requirements of organic solvents or for centralized separation and purification. At present, some large-scale flexible packaging gravure printing enterprises have begun to recycle exhaust gas (solvent). Whether it is the adsorption recovery method or the regenerative catalytic combustion method, it is believed that the flexible packaging gravure printing enterprises can obtain certain economic benefits and society. benefit.

Non-benzene of gravure ink and application of integrated ink

With the concept of environmental protection and sustainable development becoming more and more popular, the relevant national environmental protection policies have shifted from the “legal law-abiding” stage to the law enforcement strict stage, and the terminal enterprises have higher requirements for environmental protection, so the flexible packaging gravure industry The process of non-benzene will inevitably accelerate.

A major technological advancement from benzene-containing inks to benzene-free inks and flexible packaging gravure industry is another innovation in the ink industry's environmental technology. Leading companies in the industry and some small and medium-sized enterprises have begun to use benzene-free inks. However, in the case of small businesses, inks containing benzene (toluene, xylene) are still the mainstays, and they are in urgent need of regulation.

At present, integrated inks have been used in large areas of large-scale flexible packaging gravure printing enterprises, which will become an important development direction of gravure inks.

(Excerpt from Ma Pingdong's article "Development Opportunities and Transformation of Soft Packaging Gravure Industry", " Printing Technology - Packaging and Decoration", October 2014)

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