Author: University of Shanghai Science and Technology Publishing and Printing College Wang Xiaohong
With the vigorous development of the press and publishing industry, newspapers and other media have formed a new situation of competition and complementarity. For example, how to make use of its own advantages to make up for the relatively long publishing cycle of newspapers, timeliness lags behind radio, television and Internet, the development and application of new newspaper printing technologies have played a great role. At present, in order to shorten the printing time of newspapers and increase the competitiveness of vigilant newspapers, doujin newspaper printing machine manufacturers around the world attach great importance to the research and development of new technologies and new products. The following is a brief introduction to these new technologies.
Waterless offset printing technology
Traditional offset printing technology uses the principle of ink-water repellence and non-ink balance to realize the transfer of dots. The technical difficulty in offset printing is to control the balance of water and ink, because this is the key to restricting the quality of offset printing. There are many factors that affect the balance of water and ink, such as the temperature and humidity of the production workshop, printing speed, paper properties, and printer performance. The waterless offset printing technology can ensure the smooth progress of the printing process without using fountain solution. The blank part of the printing plate is a silicone rubber layer that repels ink. The ink used for printing is a special waterless offset printing ink.
Since waterless offset printing does not have the problem of water and ink balance, it has many advantages.
1. Eliminate the troubles caused by the control of water and ink balance, eliminate the complicated adjustment work of water and ink balance and the water supply, water delivery and related control parts, and eliminate the deformation of paper and the change of tape tension caused by the presence of water Eliminates the need to compensate for paper deformation.
2. Reduce the waste of paper, greatly reduce the waste paper rate, thereby reducing printing costs.
3. By controlling the ink temperature through the operation window, the ink performance is improved, so the image color is clear, the printing quality is high, and the auxiliary time is shortened.
4. Problems such as ink emulsification, dirty plates, mechanical corrosion, and environmental pollution due to wetting fluids no longer exist.
Practical waterless offset printing scheme was launched by TORAY (Dongli) in Japan on Drupa 1977. On subsequent Drupa 2000, TORAY and KPG launched thermal CTP waterless offset printing plates, while Presstek, Adast and Xerox cooperated Launched thermal PAX waterless offset printing plate. The earliest application of water-free offset printing technology in the field of newspaper printing was the German KBA company. On Drupa 2000, KBA launched the Cortina newspaper printing press.
At present, waterless offset printing technology has just started in China. Plates and inks still rely on imports, so the price has remained high, which has affected the development of waterless offset printing technology in China, but the advantages of this technology have shown its Good application prospects.
No ink key technology
The inkless key technology abandons the traditional ink delivery method and replaces it with a digital ink supply control system controlled by a stepper motor. This technology is the key to the realization of digital process flow, which can realize remote control and adjustment. The inkless key technology eliminates the need for ink color adjustment in color newspaper printing and greatly reduces the scrap rate. Qualified color newspapers can be obtained within 10 copies after the clutch is pressed. Compared with the conventional production of 300 ~ 500 copies of the startup waste, the paper is greatly saved.
No main drive shaft technology
From the perspective of users purchasing equipment, they are mainly concerned about the production speed, degree of automation, stability and scalability of newspaper printers. In addition, simple maintenance, low noise, and low waste rate are also the main considerations for users. Based on these, the shaftless newspaper presses introduced in the mid-1990s were accepted and adopted by most users. According to statistics, 70% of the purchase contracts signed by domestic newspapers in 2000 were shaftless newspaper printers. At present, 90% of the equipment produced by several major newspaper printing equipment manufacturers around the world uses shaftless technology.
The main shaftless technology is referred to as the shaftless transmission technology. Compared with the shafted transmission, it means that the power drive of each unit, even each drum or roller, is independent of each other. They are controlled by a separate motor according to the program. Drive to meet the requirements of specific operating speed, operating accuracy and printing process. This technology replaces the traditional mechanical shaft with an electronic shaft, so it is usually also called independent drive, vertical motor drive, no mechanical drive, electronic shaft drive, etc. The form of shaftless transmission is various, from the unit to the drum and the main transmission roller can be used shaftless transmission. Shaftless drive is based on a single drive, so it is sometimes called direct drive. It must meet the independent adjustable speed of the specific transmission mechanism (drum, roller), with a high balance (speed matching), which can improve the flexibility of production, the simplicity of the transmission system and the convenience of operation.
Compared with the shaft transmission, the advantages of the shaftless transmission are mainly manifested in the following aspects.
1. The transmission is accurate, the mechanical wear, playground and mechanical vibration are small, which eliminates the maintenance work of each transmission component in the shaft transmission, which is conducive to the improvement of printing quality and reduces the scrap rate.
2. It is convenient to realize the computer console control and remote control of the printing press.
3. The unit configuration is flexible, which improves the utilization rate of equipment and increases the flexibility of production. It is especially suitable for flexible and short-form live printing.
4. Each part can be prepared and adjusted separately, which saves production preparation time and installation and adjustment time, and saves precious time for ensuring publishing.
5. In the production process, the fault maintenance of any unit will not affect the normal production of other units, ensuring the continuity of printing and the stability of quality.
However, the shaftless transmission technology is not perfect, and it requires a large investment. The increase in the control equipment of the allies and the increase in the complexity of the system put forward higher requirements for the skills and experience of equipment manufacturing, maintenance personnel and operators. On the basis of mastering the traditional printing process, the operator must also have a certain electronic technology and English foundation, so that this new technology can play a greater role.
Seamless technology
The rubber blanket of the traditional printing machine will easily cause ink sticks due to the vibration caused by the collision of the plate seams when the interfaces meet. In 1993, Heidelberg invented the seamless cylinder blanket, because there are no seams, which eliminates the vibration of the cylinder to ensure the quality of newspaper printing. This seamless blanket has dynamic stability and can obtain high-quality prints even under high-speed printing of 80,000 copies / hour. Compared with traditional blankets of the same circumference, the use of seamless blankets can increase the effective printing area and reduce the cutting size, thereby significantly reducing paper waste. Another notable feature is that it is extremely convenient to replace, and it can usually be replaced within 1 minute without disconnecting the roll paper.
Seamless technology further improves the speed of newspaper printing presses, and makes future newspaper printing presses more competitive in terms of printing capabilities, production efficiency, and economic benefits.
CTP technology
CTP technology is a general term for offline direct plate-making, on-board direct plate-making, and direct printing package technology. Because it simplifies the plate-making process, there is no data loss, and the dots are sharp, the dot reproducibility is good, the plate-making cycle is short, the plate-making time is short, the entire production cycle of the printed matter is shortened, and the printing quality is excellent.
The reason why CTP technology can develop rapidly in the field of newspaper printing is mainly because of its fast speed and high quality, which is very suitable for the high aging time required by newspaper printing. Although the CTP system requires huge investment, large newspaper groups generally have strong bonuses and strong technical force, and can actively accept and adopt new technologies. Therefore, CTP technology has been rapidly developed and applied in some major domestic newspaper groups. According to incomplete statistics, the number of CTP systems installed in China's newspaper industry currently exceeds 40.
In the traditional plate-making process, the time required for printing and proofing is relatively long. Only proofs can be printed and printed after being approved by customers, and the transportation and management of the film may also adversely affect the printing quality. For newspapers with strong timeliness and need to be printed in different places, these defects of the traditional process have become an important factor restricting the development of newspaper printing.
The entire process of the CTP process processes and transmits digital information. At the same time, digital proofing technology is also applied. Therefore, the advantages of CTP technology in replacing the traditional plate-making process are obvious. It simplifies the process, saves publishing time, and improves the quality of printing This reduces personnel and venues, reduces the complexity of equipment maintenance, and reduces environmental pollution. According to calculations, CTP technology can save about 70% of pre-press working time and shorten the plate-making time by nearly an hour. At the same time, due to the vitality of the film, the overprint accuracy and dot quality of color prints are reliably guaranteed, and the alignment error is only about 0.002mm, which solves the problems of manual extraction and labor-consuming and poor accuracy, and reduces the startup preparation time. From the perspective of printing effects, the traditional plate-making process can only reproduce 5% to 95% of the dots, while the CTP process can reproduce 2% to 99% of the dots; newspapers printed with CTP technology have more delicate and rich layers and more vivid colors; Due to the reduction of intermediate links, the accumulation of quality errors has significantly decreased, and the quality controllability has been significantly enhanced. Because the CTP technology reduces the loss of dots on exposed film and printing plates, it also makes the application of FM networks possible.
CIP3 digital workflow
The printing technology has undergone the development process of lead type typesetting → photographic plate making → electronic color separation plate making → laser phototype making (CTF system) → computer direct plate making technology (CTP) → CIP3 technology. Among them, electronic color separation and plate making and DTP systems are widely used in the printing field, and the digitalization of pre-press graphic processing has been initially realized; the CTP technology that is being used and developed is the key link to realize the comprehensive digitization of plate making and printing; and the latest in the printing field The concept of CIP3 is to achieve the full digitization and information sharing of pre-press, printing, and post-press before and after printing and digitization, which is the goal pursued by printing technology in the new century. The digital technology in the modern printing field for the past ten years is mainly used in the pre-press processing stage. With the development of CTP technology, digital technology has begun to get involved in the printing field, and post-press digitalization is still at an undeveloped stage in China. With the further development and application of new technologies. The concepts of diversification, networking and comprehensive digitization have emerged in the printing field, and CIP3 is a brand-new printing technology under this big concept.
The CIP3 digital workflow has the feature of inputting all relevant departments and production stage data information at once and sharing with each part, which can avoid repeated input and recalculation of printing production data, thus shortening the work cycle and reducing the incidence of failures. In addition, the relevant data information can be transferred to the printing and post-press processing workshop in the pre-press stage, so that the operator can make preparations early.
With the continuous improvement of the level of printing automation, the trend of newspaper printing in pursuit of time and efficiency is more obvious. The CIP3 digital workflow has the characteristics of reducing production costs, shortening printing time, and reducing the rate of printing waste, which makes it very suitable for application in the field of newspaper printing. However, at present, there is still a certain distance between domestic enterprises in terms of capital, technology, concept, etc., so it is still difficult to widely apply CIP3. In addition, because the newspaper itself does not have high requirements for printing quality, post-press processing is relatively simple and fixed, which also makes the advantages of CIP3 not fully exerted. However, with the development of technology and the change of concept, CIP3 is still very optimistic about the future of the newspaper industry.
Flexo printing
At present, all newspaper printing machines used and introduced in China are offset printing presses, and flexographic printing newspapers abroad also occupy a certain proportion. With the enhancement of people's awareness of environmental protection, the application of flexographic printing in the newspaper printing industry will enter the practical stage, and there is a certain room for growth.
The use of flexographic printing for newspaper printing began in the United States in the mid-1970s. In 1982, the United States launched a newspaper printing specialty and a flexographic printing machine. Since then, flexographic printing has been competing with offset printing in the field of newspaper printing. Today, about 30% of newspapers in the US use flexographic printing, and about 14 major newspapers in Europe use flexographic printing. Among them, about 25% of newspapers in Italy use flexographic printing. Compared with offset printing, flexographic printing has the following advantages:
1. The equipment cost is lower than the offset press. Under the condition that the size of the substrate and the printing capacity are the same, the equipment cost of the flexographic printing machine is about 1/3 lower than that of offset printing.
2. Printing speed is higher than offset printing machine. Because flexographic printing is light pressure printing, sleeve printing plates can also be used. The inertial imbalance is small, the paper is not easy to break, and it has good running stability, so it is suitable for high-speed printing.
3. Flexographic printing can use low-quantity newsprint. Because the operation stability of the flexographic printing machine is good, and there is no impact of the fountain solution in offset printing on the performance of the paper, low-quantity newsprint (40 ~ 45g / m2) can be used for flexographic printing, and the offset paper cannot Thin, general quantitative can not be lower than 48g / m2. If thick paper is changed to thin paper, and the annual printing of 54 billion pairs is calculated, the average annual newspaper printing paper can be saved by 18%. For newspaper printers, it can greatly reduce costs. For short-run newspaper printing, flexographic printing has the advantage of low cost.
4. The rate of waste paper in flexographic printing is low. The adjustment and trial printing time of flexographic printing is shorter, so the waste paper rate is lower, about 2%, which is 9% lower than offset printing. If the amount of paper saved by the use of thin newsprint is added, only paper paper can save about 27% of paper annually. According to reports, due to the use of flexographic printing in the San Francisco Observer, the paper alone can save about 41 million US dollars per year.
5. Easy to operate. The technical requirements for flexographic printing are not very high, and the reduction of start-up personnel also reduces labor costs.
6. Good for environmental protection. Flexographic printing uses water-based ink, there is no problem of solvent volatilization and discharge, and there is no problem of solvent treatment when cleaning the machine and rubber roller. The recovery and utilization of water-based ink is also easier than that of offset printing ink. In addition, the water-based ink has the characteristics of fast drying, and there is no problem of smudging, so readers will not stain their hands or other objects when reading.
7. The printing quality is good. Flexographic printing has the advantages of embossing, graphic and artistic workers are clear, the picture is neat, the colors are bright, and the printing quality is better than offset printing. At the same time, flexographic printing has good printing repeatability, which can ensure that the ink color of the printed product is consistent, and it is convenient and efficient to realize multi-color printing.
8. The successful development of flexographic printing CTP system and the application of digital workflow in flexographic printing have made flexographic printing technology follow the development trend of printing technology and can adapt to the requirements of modern newspaper printing.
At present, the application of flexographic printing in the domestic newspaper industry is mainly restricted by factors such as concept, investment order and operator. At present, the printing equipment used in the newspaper industry are offset printing presses, and they continue to invest in a more stable way to purchase offset printing presses. In addition, due to the relatively small proportion of flexographic printing in the domestic printing field, there is a lack of talents and technical experience, which also restricts the promotion and use of flexographic printing machines in China. However, because of its unparalleled advantages in certain aspects, it is believed that in the near future, flexographic printing will definitely have a breakthrough and development in the field of newspaper printing in China.
Digital printing technology
Digitalization and networking, which have run through the entire printing industry, are the foundation and theme of today's printing technology development, and are building a brand-new production environment and technical foundation. In digital printing, the digital files formed by pre-press processing do not need to be printed out immediately, but are stored in the system in digital form or transmitted to other places through the network, and finally the printed output is completed according to the customer's ordering needs. Obviously, this is a brand-new production method based on "digital process + digital media + network transmission", which can realize digital 100% variable information printing. Printing and publishing are not limited by time and region. With high speed, diversification and meeting different needs, newspaper on-demand printing is possible.
Newspaper digital presses were introduced in Drupa 2000, when several companies introduced newspaper presses. Among them, the roll paper digital printing machine DICOweb launched by Manroland uses thermal transfer imaging technology to directly image on the plate cylinder. The plate-making time of each print does not exceed 10 minutes, and there is no need to change the print and do not need offset; The digital printing system uses an electrophotographic system developed with dry toner; at the same time, TruePress 744 with a screen and the the and factory of Agfa are also launched.
With the substantial increase in the printing speed and printing quality of digital printing presses, the sharp drop in the price of printing materials and the expansion of the use of paper, digital printing will occupy a certain market in the field of newspaper printing.
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