Due to the intense competition in today's market, there has been a significant rise in short-term tasks within gravure plastic printing. As a result, plate-making costs now often account for over 50% of the total production cost. This makes it essential to find ways to reduce these expenses effectively.
Upon closer examination of plate-making costs, it becomes clear that each set of printing plates includes a full white background plate. This raises an important question: can we save on plate-making costs by using just four full-white plates instead?
**Four Approaches to "Save" the Full-White Plate**
The primary purpose of the white background is to serve as a base color, enhancing the opacity of the plastic film and allowing other colors to appear more vibrant. Ideally, the white background could be used as a single unit. However, in practice, due to limitations in the structure of printing machines, different-sized printing plates cannot be used simultaneously. Therefore, each set of plates must include its own white background. So, how can we "save" on this white version?
Here are four practical options:
1. **Modify the Printing Press Structure**: Replace the current motor-driven system with independent motor drives for each unit, ensuring consistent surface linear speed across different plate cylinder sizes.
2. **Use White Inner Composite Material**: Introduce a white inner layer that acts as a substitute for the traditional white plate, reducing the need for separate white plates during printing.
3. **Install a White Plate Coating Device**: Add a coating device behind the existing press to apply white ink directly onto the film after other colors have been printed.
4. **Adjust the Printing Process**: Print all other colors first, then apply the white ink in a second pass on the same machine.
**Feasibility Analysis of the Four Options**
From a technical standpoint, each option has its own advantages and challenges:
1. **Modifying the Press Structure**
*Pros*: No changes to the original process, no additional equipment needed.
*Cons*: High technical complexity, risks involved, and requires advanced mechanical and electrical capabilities.
2. **Using White Inner Composite Material**
*Pros*: Proven feasible through small-scale trials, low risk, and increases the number of printable colors.
*Cons*: Higher material costs, stricter color control required during printing.
3. **Installing a White Plate Coating Device**
*Pros*: Technically straightforward, increases print capability without extra material costs.
*Cons*: Requires investment in new equipment, and color control remains challenging.
4. **Second Pass White Ink Application**
*Pros*: No additional material costs, allows for more color flexibility.
*Cons*: Increases machine wear, extends production time, and complicates the first print run.
After evaluating all options, the best approach is to combine methods 2 and 4. The choice between them should depend on the specific job and the condition of the printing press. According to internal testing, implementing this combined strategy can lead to a 6% reduction in overall costs for similar short-term tasks. This not only improves efficiency but also enhances competitiveness in the ever-evolving printing industry.
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