Chocolate Packaging Printing Register Problem Solving Example 2

Tension control system

Last year, when Astor's printing department tried to complete an already outsourced packaging printing task, its printing capacity reached its limit. This package, that is, the film packaging bag, requires a film structure in order to achieve the safety of the seal. However, the thickness of this film has made it practically impossible for Astor to control both the stretch rate of the film and to fully maintain the film tension for registration.

When installing the Cygnus system, MAGPOWR worked closely with Astor to put all the components in place and then cut off the power of the original press, thus minimizing the downtime of the press. After the power was turned off, the installation team used the original pressure sensor, clamp, and Cygnus controller to start the wiring and establish the connection. With MAGPOWR's assistance, a minor problem with the pressure sensor connector was resolved on the spot, Rouze said, and the system was installed in less than one shift. A few days later, Shingle & Gibb provided additional training and fine-tuned the system.

The Cygnus system consists of a magnetic particle gripper, a pressure sensor, an ultrasonic sensor, an independent power supply, a torque controller, and multiple tension controllers. The operator systematically plans advanced tension control functions and codes using the prompts displayed on the screen in full text. The versatility of the smart key allows you to maintain and adjust the film tension. After the planning is complete, one of the controllers will talk to Cygnus to provide a change in the diameter of the roll. The diameter of the roll directly affects the tension of the film, which is related to the inertia formed by the momentum of the roll. The Cygnus system compensates for larger and heavier volumes by calculating the diameter of the roll, and is used during the use of each roll.

Astor purchased an eight-color flexo press to obtain the same print quality as offset printed labels and bags.

The success of the new system

Astor installed the Cygnus system a week later and received a printing order from New York's Dylan Candy Company. Rouze said: "This is a real test of the system. This is an eight-color printing business, four are process colors, four It is a spot color. The customer's logo consists of concentric circles of three primary colors."

“Everyone here understands immediately that concentric trapping is one of the most difficult job done on any press. Not only that, this print job must also be transparent 1.6 mils The finished polypropylene film was finished, and we used a 1 mil, self-wrapping polypropylene coating."

Of all the factors that determine the quality of the printing, it is of utmost importance whether the machine can perform accurate registration.

"The challenge is not just to print a color picture on the film, we have to try to print a concentric design with a 0.005-inch circle."

“Using the Cygnus system, the operator reduced the tension at the time of unwinding and adjusted the reaction of the floating roller by pressing a few buttons. After a few minutes, we aimed at the pattern and kept the registration. However, I still can't be sure Because we haven't had a film yet. When we cover the film, there is a slight increase in tension after the machine starts up, and then it stays steady. This is an amazing success."

According to Rouze, the Cygnus tension control system shows us three advantages: not only improving the quality of Astor's existing print operations, but also bringing new business to the company. It also greatly reduces the setup time and preparation time of the machine. He said: "Our waste has been reduced from 15% to a little more than 3.5%. Considering that most of our business is short-term printing business, we have saved a considerable amount of money." At the same time Astor also obtained from its efforts. The return.

PACKAGING