Gravure printing has long faced criticism for environmental issues, particularly volatile organic compound (VOC) emissions. As global awareness of sustainability grows, green gravure has become essential for the survival and growth of printing companies. To fully embrace eco-friendly practices, businesses must go beyond using environmentally friendly materials and upgrading equipment—they should also focus on optimizing production processes to minimize waste and achieve both environmental protection and economic benefits.
1. **Print Layout Design**
When designing layouts, aim to deliver the best visual quality with the simplest and most efficient design. For example, use smaller sizes and appropriate colors for color marks, slit marks, and bag-making marks to reduce material loss. Minimize the number of spot color plates and replace them with primary colors where possible. Reducing color count and optimizing layout can lower ink usage and improve efficiency.
2. **Production and Use of Printing Plates**
In the plate-making process, prefer filmless electronic engraving to reduce chemical corrosion. Store and handle plates carefully to extend their lifespan. Good operating habits significantly affect plate durability. If a plate wears out, dechrome and replate it promptly instead of waiting for copper exposure. Scrapped plates should be recycled at the manufacturer.
3. **Ink Viscosity Control**
Ink viscosity directly affects print consistency. Poor control can lead to excessive waste. Use automatic viscosity control systems or solvent addition methods to maintain stable viscosity. For expensive inks, use smaller tanks to minimize leftover ink. Wrap tanks with waste film to reduce cleaning efforts and solvent loss. Clean used tanks thoroughly to minimize residue.
4. **Spot Color Ink Mixing**
When mixing spot colors, record the ratios and create samples. Compare new mixes with the sample before printing to ensure color consistency. Advanced companies can use computer-assisted color matching to improve accuracy and reduce leftover ink.
5. **Scraper Selection and Maintenance**
Scrapers are critical components that wear over time. Replace them after a certain amount of printing or when changing plates. Reduce replacement frequency by adjusting scraper angles, increasing plate hardness, and keeping ink clean. Used scrapers can be reused after polishing or used in less demanding jobs. Coated or combined scrapers can enhance print quality while reducing costs.
6. **Material Roll Management**
Minimize material waste during setup by aligning plates properly or using scrap to adjust registration. Precise tension control ensures high-quality prints. Prepare new rolls in advance for continuous feeding. When large registration errors occur, switch to an automatic system after manual adjustment to avoid waste. Accurate records help speed up future setups.
7. **Workshop Environment Control**
Maintain proper temperature, humidity, and cleanliness in the workshop. High temperatures or dry conditions may require slow-drying solvents, increasing drying load and solvent residue risks. Use humidification systems in dry seasons to reduce static and improve shallow screen printing. A clean environment prevents dust from causing print defects like knife lines.
8. **Waste Recycling**
Seal unused ink in containers and reuse it as black or special color ink. Recover solvents from non-reusable ink. Use waste plastic films for protective packaging. Sort rags to minimize waste after cleaning. Collect and recycle all printing-related waste—films, paper, aluminum, cartons, and more. Ensure proper disposal of cloth, sand nets, and other materials through designated recycling stations.
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