With the development of the times and the improvement of technology, gravure printing, which has made great contributions to the packaging industry, has begun to face market challenges and baptisms after nearly 20 years of rapid development: environmental protection is a major problem facing gravure printing As early as 20 years ago, European and American countries have legislated to protect the environment and made regulations and restrictions on VOCs emissions. In China, VOCs emissions governance has just started, and many problems need to be resolved. The requirements for the development of clean energy and reducing energy consumption are within the industry. Increasing calls; equipment should be more intelligent; the market has higher and higher requirements for equipment efficiency and working environment; customers require full control of the entire production process of products; “quantified value” is the only way for customers to evaluate and determine their investment Ways… These problems seem to be intricate, but a detailed analysis and summary show that the development trend of gravure printing is: environmental protection, energy saving, and smart factories.
In 2012, the State Council formally approved the “Twelfth Five-Year Plan for the Prevention and Control of Air Pollution in Key Areas”. For the first time, the control of volatile organic compounds was regarded as an important part of the environmental impact assessment of construction projects. For the first time, the treatment and emission reduction of VOCs were specified in a national document. purpose. The “Plan” mentions that “the control of volatile organic compounds shall be regarded as an important part of the environmental impact assessment of construction projects, and strict pollution control measures shall be adopted”, and it is proposed that key control areas, key emission companies, and companies in key areas will be subject to strict Monitoring and management. And recently, a series of national and local regulations have been promulgated, which are aimed at the printing industry. For example, Beijing, for existing printing companies, an additional 2,000 to 2,500 yuan will be charged for each ton of solvent used; Shanghai will be released this year. VOCs emissions from the printing industry will be banned at the end of the year; Jiangsu will ban VOCs emissions from the printing industry in mid-2016. These stringent regulations are promoting product upgrades and corporate transformation in the industry.
The treatment methods for VOCs include recovery, RTO thermal storage and oxidation, but my country’s related technologies are not very mature, and there are still many problems, such as rapid decline in adsorption rate, solvent acidification, safety issues, and late separation treatment of mixed solvents that cannot be solved well. ,and many more. In fact, adopting a set of effective methods and high-quality equipment is the law to deal with the problem. The author believes that the process of adsorption-recovery-condensation-rectification can be carried out on the discharge of a single solvent, so that high-purity solvents can be recycled, which is environmentally friendly and economical. For mixed solvents, RTO treatment can be used to reuse heat energy. In addition, prior to the implementation of these two VOCs treatment measures, the original equipment can be modified and the LEL safety cycle device can be installed, which can reduce the investment of VOCs recovery and RTO thermal oxidation equipment by more than 40%.
In the printing process, a large amount of heat energy is consumed while VOCs are discharged. The heat energy consumed is the latent heat of vaporization of the solvent required for printing and drying itself and the waste heat taken away by the VOCs tail gas. Calculated according to the amount of solvent used in traditional printing, the theoretical heating power of a color group is 5-10KW, but the actual drying power is often 30-72KW, or even higher. The energy consumption required for drying in the printing industry accounts for 2% to 5% of the entire product cost, and the profit of the traditional printing industry is maintained at this level. Therefore, if there is a technology that can reduce the drying energy consumption of traditional printing Half, then it means that the company’s profits will double. In the application of high-efficiency energy-saving measures, Shaanxi Beiren took the lead in introducing two high-efficiency energy-saving methods in China: heat pumps and heat pipes. When the drying temperature required for printing is lower than 100°C, a heat pump can be used, and when the drying temperature required for printing is higher than 100°C, a heat pipe is used.
The heat pump can usually save energy by 60%~70%. At present, 25% of printing companies in the country use electricity as heating energy. If these printing companies switch to heat pumps, the national printing industry can save 1.02 billion kilowatt-hours of electricity each year, which is equivalent to the total power generation of the Liujiaxia Hydropower Station in two months, which is equivalent to Reduce 100,000 tons of carbon dioxide emissions. As of September this year, there have been more than 1,000 installed heat pumps nationwide.
Heat pipe technology has been widely used in aerospace, military industry and other industries before. Since being introduced into the radiator manufacturing industry, people have changed the design thinking of traditional radiators.
The working principle of the heat pipe heat exchanger is: exhaust air passes through the evaporating end of the heat pipe heat exchanger, one end of the heat pipe is heated, the medium liquid in the capillary tube evaporates quickly, the steam flows to the other end (condensing end) under a slight pressure difference, and the fresh air passes through At the condensing end, the medium vapor in the heat pipe is cooled to release heat and recondenses into a liquid. The liquid flows back to the evaporating end along the porous material inside the heat pipe by capillary force, and the cycle continues, and the heat is transferred from one end of the heat pipe to the other end. . The heat transfer of the heat pipe is carried out by the phase change of the medium in the pipe, which is efficient and rapid, and its heat transfer efficiency can reach more than 60%. Because it is designed according to the principle of evaporation, the higher the working temperature zone of the heat pipe, the more obvious the energy-saving effect. The energy-saving is usually 35% to 55%.
Smart manufacturing and smart factories, which are born under the background of global Industry 4.0, have rapidly expanded. Nowadays, many industries such as automobile manufacturing, chemical industry, logistics, etc. are undergoing changes, and industry 3.0 is used as the foundation to move towards Industry 4.0. Traditional printing companies rely on the skills of workers and paper-based information flow to produce. They are low in efficiency, consume energy-intensive materials, are large but not sophisticated, and lack market competitiveness. It can be said that my country’s printing industry is still in the industrial 2.x era, or even lower. Based on the characteristics of the printing industry, Shaanxi Beiren formulated a digital-based smart factory development model for the printing industry.
The printing and packaging smart factory is a complex and huge system, which is mainly composed of four parts: smart logistics system, enterprise management software, production information collection system, and smart production equipment. Through the collaborative work of various systems, an intelligent digital factory with complete functions and a high degree of automation is constructed. In the intelligent digital factory, equipment and equipment interconnection, people interconnection, people and equipment interconnection, that is, the physical objects in the system communicate in the information system and conduct cross-border information exchange. The various systems achieve cross-over integration.
In the printing and packaging smart factory, the printing and packaging equipment is no longer the only or independent main production equipment, but a link in the entire intelligent production process. The entire system is coordinated to achieve intelligent scheduling-from the intelligent warehouse to automatically transport materials to the printing equipment; the operator of the printing equipment does not need to load and unload the rolls, the intelligent equipment can automatically complete the up and down rolls; the process parameters of the entire equipment are sent by the MES system To the device, the device automatically reads and writes and completes the parameter setting. In this way, equipment operators only carry out supervision and inspection, which can reduce enterprise personnel by 50%.
Environmental protection, energy saving, smart factory, is the future development trend of gravure printing. I believe that with the popularization of the above technologies in the industry, traditional printing companies will reshuffle and integrate, and inefficient and environmentally friendly small companies will be forced to shut down and transfer, and disorderly competition in the market will become orderly competition. Let the industry move forward along the route of healthy development.