From Ink to Laser: A Complete Analysis of the Production Line

As environmental and efficiency demands continue to grow, the trend is for traditional ink production to switch over to laser technology.The book provides a comprehensive overview of the entire process of production line transformation, including equipment selection, process adjustment, cost control, and other key aspects. It helps companies to achieve efficient, low-cost application of laser technology and resolve practical problems in the course of transformation.

Why switch from ink to laser?

Over the past two years, more and more printing companies have been asking themselves how much longer they can continue to use traditional printing technology. Environmental pressures are increasing, raw material costs are high, and customers are becoming more and more demanding.Lasers are different. Not only do they save ink and cleaning fluid, they can even "engrave" directly onto metal or plastic, with precision to the micron level.But it's not a matter of just deciding to do it one day. It has to be done step by step.

Preparation for the renovation.

Clear needs and budget.

Think clearly about what problems your production line must solve.The company was having trouble meeting its delivery dates and the quality of its products was too low. There are many different kinds of laser equipment, and the price of fiber optic lasers and CO2 lasers can differ by several times. Don't just go with the "flashy" ads. Choose based on your actual needs.

Evaluate the compatibility of existing equipment.

Can the conveyors and control system of the old production line be connected to the laser heads? A technical team has to be sent to the factory to find out.Some plants bought new equipment in order to save time, only to find out that the plant's power supply was inadequate, which only delayed things.

The environmental impact assessment and safety review are completed.

Although laser equipment does not use chemical inks, it does require protection against radiation.Communicate with the relevant authorities in advance and don't wait until the equipment is installed to find out that you need to fill out a bunch of forms.

The key step to change.

Choosing the right laser equipment supplier.

There are so many brands on the market that it can be overwhelming, but the main thing to look for is the speed of response to service calls and the availability of local technical support.One factory in Guangdong bought a laser machine at a low price, but when it broke down, it took three months to get replacement parts.

Adjusting the process parameters.

The power of the laser, the focal length, and the scanning speed are all parameters that directly affect the quality of the final product.It is suggested to first use waste materials to test the system and record the best combination of parameters for different materials.Don't blindly trust the "standard parameters" given by equipment manufacturers, because the actual production environment's temperature and humidity will affect the results.

Training has to be down to earth.

The old craftsmen, accustomed to using printing presses, found themselves suddenly having to use computer-controlled laser equipment.Training shouldn't just be a matter of theory, but should get the employees right to work on a few samples, and any problems can be dealt with on the spot.

How to lower costs and increase efficiency after a restructuring.

Cost of consumables.

Ink factories spend upwards of NT $ 10,000 a month on cleaning solutions. Laser equipment is mainly energy-consuming, but the electricity bill for the same output is 60 % lower than for the traditional method.However, the lenses and laser tubes have to be changed regularly, so don't forget to factor this into the long-term costs.

A few tips to keep your computer in good shape.

The laser heads are most afraid of dust, and a new air-conditioning system in the workshop can extend their life.The technicians are taught to use alcohol to clean the lenses, but never to use tissue paper to wipe them, because a technician from another factory once did that and ended up with scratches on the lenses that caused the entire batch of products to be scrapped.

The hidden advantages of flexible production

Changing designs with laser equipment requires only changing the computer files, not replacing the molds.Last year, a toy factory in Zhejiang province used the function to receive 20 orders in three days.

A guide to common pitfalls.

Don't think that just because the work is done everything will be fine! The most laughable case I've ever encountered was a food packaging factory that replaced its inkjet printer with a laser coder, only to discover that PET packaging deforms when heated. In the end they had to install a cooling system.Therefore, it is essential to do a complete material test before the reconstruction.

In short, the shift from offset to laser is not as simple as "changing a machine." It's a step up in the production process and in management thinking.If you put in the time to plan at the start, you can really reap the benefits of technological innovation later on.