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Over the past two years, with the continuous advancement in the overall level of domestic printing machinery manufacturing, gravure printing equipment has seen ongoing innovation and achieved impressive results. These technological improvements are helping to enhance efficiency, reduce labor intensity, and improve product quality across the industry.

Automated Winding and Unwinding Technology

Modern gravure printing machines now feature fully automated winding and unwinding systems. This technology allows for the automatic lifting of rolls with varying diameters and widths to the clamping station through precise measurement and detection. Once there, the lifting device automatically moves the finished roll away from the operator. During this process, the system automatically detects the weight of both raw materials and finished products, connecting production management seamlessly. This automation eliminates the need for manual handling, overcoming previous bottlenecks and significantly increasing productivity while reducing the physical burden on workers.

Automatic Cutting Technology

With the implementation of fully automatic cutting technology, the entire cutting process becomes much more efficient. Operators only need to place the material roll on the discharge rack, and the machine handles the rest without human intervention. For example, when cutting a BOPP film with a thickness of 0.018 mm, the system can keep the leftover material within 10 meters. This not only reduces dependency on operators but also improves work efficiency and ensures consistent quality in the output.

Intelligent Pre-Registration Technology

The intelligent pre-registration system streamlines the initial setup of the printing process by eliminating the need for manual alignment using rulers. Instead, it uses the keyway on the plate roller and corresponding marks on the plate for accurate positioning. The system then automatically confirms the zero point, allowing for quick and precise initial calibration. Afterward, the system calculates the color interval and rotates the plate roller to the correct position for automatic pre-registration, ensuring smooth and accurate print alignment.

Semi-Closed Ink Tank with Lower Transfer Roller

This design helps prevent ink squeaking at high speeds and minimizes the evaporation of organic solvents, maintaining stable ink performance during high-speed printing. It also reduces ink recycling from about 18L to 9.8L. The gap between the lower transfer roller and the plate roller is maintained at 1–1.5 mm, which enhances ink transfer efficiency and improves the reproduction of shallow network tones, resulting in better print quality.

Intelligent Data Management System

The intelligent data management system enables real-time monitoring of machine parameters and status, storing essential data for future reference. It also accepts remote process parameters and order requirements, ensuring that only authorized commands are executed. This integration allows for seamless communication between on-site and remote systems, improving operational control and efficiency.

Digital Tension Control

Digital tension control replaces traditional manual valve settings with a user-friendly interface where operators can directly input the desired tension values. Each section of the machine displays its tension level digitally, making it easier for operators to monitor and adjust. This system reduces reliance on manual adjustments and enhances the machine’s overall intelligence and performance.

Hot Air Energy-Saving Technologies

Several energy-saving technologies are now being used in gravure printing equipment, including heat pump heating, heat pipe technology, and fully automatic hot air circulation systems with LEL (Lower Explosive Limit) control.

  1. Heat Pump Heating: Heat pumps are far more energy-efficient than electric heating. Using an air-source heat pump can save up to 60%–70% in energy consumption.
  2. Heat Pipe Technology: This system recycles heat efficiently by using secondary return air and heat exchangers, reducing energy waste and improving thermal efficiency.
  3. Automated Hot Air Circulation with LEL Control: This system maximizes the use of secondary return air while ensuring safety, saving around 45% in energy and reducing exhaust emissions by 30%–50%. It also lowers future investments in pollution control by 30%–40%.

The above content is reprinted from the official WeChat account "Printing Technology" (Printech1957), authorized by the company for publication. Copyright is reserved; any unauthorized reproduction will be investigated!

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