Gravure printing has long faced criticism for environmental issues, particularly volatile organic compound (VOC) emissions. As the global push toward sustainability continues to gain momentum, green gravure has become essential for the survival and growth of gravure companies. To fully embrace greening in gravure printing, it's not enough to simply use eco-friendly materials or upgrade equipment. Companies must also focus on optimizing production processes, minimizing material waste, and achieving both environmental and economic benefits through efficient resource management.
One key area is **print layout design**. Designers should aim to achieve high-quality output with minimal complexity. For instance, using smaller and more appropriate sizes for color marks, slit marks, and other registration elements can reduce substrate waste. Reducing the number of spot color plates and replacing them with primary colors helps cut down on ink and plate usage. Additionally, optimizing the layout to lower the overlap of printed areas can further enhance efficiency.
In terms of **printing plate production**, the use of filmless electronic engraving reduces reliance on corrosive chemicals. Proper storage and handling of plates are equally important—ensuring durability by maintaining good operating habits. When wear occurs, plates should be re-chromed promptly instead of waiting until copper exposure happens. Scrap plates should be recycled to minimize waste.
**Ink viscosity control** plays a crucial role in reducing printing defects. An automatic viscosity control system or solvent compensation methods can help maintain consistent ink quality. For expensive inks, using smaller ink tanks and covering them with waste film can reduce cleaning efforts and solvent loss. Proper cleaning of used ink tanks minimizes residual ink.
When mixing **spot color inks**, samples should be saved to ensure consistency between batches. Comparing new mixtures with stored samples before printing ensures color accuracy. Advanced companies may also use computer-assisted color matching systems to improve precision and reduce leftover ink.
The **scraper** is another critical component. Due to wear during high-speed operation, regular replacement is necessary. However, adjusting scraper angles, increasing plate hardness, and keeping the system clean can extend their lifespan. Used scrapers can be repurposed for less demanding tasks, helping to save costs.
Regarding **material roll usage**, careful adjustment of the printing plate during setup can reduce initial errors. Using degraded materials for alignment and precise tension control improves print accuracy. Preparing new rolls in advance when switching materials prevents downtime. Accurate process records help speed up future setups, boosting overall efficiency.
Maintaining a **clean and controlled workshop environment** is vital. Temperature, humidity, and cleanliness directly impact print quality. In dry conditions, humidification systems can reduce static and improve shallow screen performance. A clean workspace also prevents dust from causing defects like knife lines.
Finally, **waste recycling** is an important part of the greening process. Ink residue should be sealed and reused where possible. Plastic films can be repurposed for packaging, and rags should be cleaned and reused. All waste materials—films, paper, aluminum, cartons, and more—should be separated and properly recycled to support sustainable practices.
By implementing these strategies, gravure companies can significantly reduce their environmental impact while improving efficiency and profitability.
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