Due to the intense competition in the market, short-form tasks have become increasingly common in gravure plastic printing. As a result, plate-making costs often account for over 50% of the total production cost, making it essential to find ways to reduce these expenses.
Upon closer examination of the plate-making cost structure, it becomes clear that each set of printing plates includes a full white plate. This leads to an important question: Can we save on plate-making costs by using a single white plate across multiple sets?
There are four practical approaches to "saving" the full white plate:
1. **Modify the printing press structure** – Transition from motor-driven units with shaft coupling to independent motor drives for the final unit, ensuring consistent surface speed across different plate cylinder sizes.
2. **Use white inner composite material** – A material that allows for a white background without the need for a separate white plate.
3. **Install a white plate coating device** – Add a device behind the existing press to apply the white color directly.
4. **Adjust the printing process** – Print other colors first, then apply the white color in a second pass.
Each option has its own set of advantages and challenges.
- **Changing the press structure** offers no additional equipment but requires high technical expertise and carries some risk.
- **Using white inner composite material** is technically feasible and low-risk, but may increase material costs and complicate color control.
- **Adding a coating device** is technologically straightforward and avoids material cost increases, but involves upfront investment.
- **Printing white in a second pass** is simple to implement but may lead to longer production times and quality control issues.
After analyzing all options, combining method 2 (white inner composite material) with method 4 (second pass white printing) seems most effective. This approach allows flexibility based on job requirements and machine conditions.
According to internal testing, this combined strategy can reduce overall costs by approximately 6% for short-term tasks. By optimizing plate usage, companies can not only cut costs but also improve efficiency and adaptability in a competitive market.
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