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Rotogravure printing
In the case of intaglio plastic printing, the proportion of plate-making fee in the total printing cost is often more than 50% (the following table). Thus, there is the need to save the cost of plate.For example :
Cost analysis of Rotogravure printing and packaging of one company
| Name | Total cost（CNY） | printing plate cost（CNY） | The proportion of plate making cost to the total cost |
| Soap packaging | 34100 | 16100 | 47％ |
| Stand up pouch | 36400 | 18400 | 51％ |
| 6ml pouch | 31100 | 16100 | 52％ |
| 25ml pouch | 33400 | 18400 | 55％ |
If the composition of plate making costs is further analyzed, it will be found that, basically, many patterns, there are full bottom white plate or other monochrome full plate printing needs. Then, can we start from the cost of plate making by finish all monochromatic full plate printing with one printing plate? Or others way ?
Usually there are 4 solutions which can use for save printing plate cost when have big demand of full plate printing
In theory, the function of full-plate printing is to use a single color (such as white) as the background color to increase the opacity of the plastic film so that other colors can be better expressed. Therefore, full – bottom white plate printing can be used as a plate roller. However, in practice, due to the limitation of the structure of most intaglio presses, plates of different diameters cannot be used in one press at the same time, so each set of plates must have its own plate for full plate printing. How to “save” the cost of the full white plate printing plate? From the perspective of implementation, there are the following solutions :
- Customized printing machine to changes the structure of the rotogravure printing machine :
Usualy the standard of rotogravure printing machine adopts main motor drive and shaft transmission between each printing unit , now change the last color printing unit adopts independent motor control to drive printing cylinder , then it can achieve even if the last printing unit with different diameter of the plate cylinder, the surface feeding speed of each printing unit remains the same. For example , our KTMS-B series machine :
- Unwind and Rewind With Double-Armed Rotary Type Design.
- Doctor Blade Pneumatic Type Design.
- Doctor Blade Moving Controlled By Separate Motor.
- Shaft-less Pneumatic Type Printing Cylinder Installation Design.
- Auto Ink Recycle System.
- With Computer Auto Color Register System and Web Video Inspection.
- Optional : standard machine with 3 / 7 Drive Tension Control System
- Optional : The last printing unit with seperate motor control , then machine with 4(3+1) / 8(7+1) Drive Tension Control System
Advantages:
Printing process same as standard machine ,easy operating
Disadvantages:
No.
2. Adopting white or other color lamianted material roll
Advantages:
- No need change machine .
- No investment, indirectly increase the printing machine can print color number.
Disadvantages:
- It has high requirements for White lamianted material quality. It increase the cost.
- It is more difficult to control color when printing.
3. Add coating device after the existing printing press
Advantages:
- Indirectly increase the printing machine can print color number, do not increase the material cost..
Disadvantages:
- It need pay for additonal machine cost .
- It is more difficult to control color when printing.
4. After printing other colors, the film will be printed again in machine with white ( or other color)
Advantages:
- Indirectly increase the printing machine can print color number, do not increase the material cost.
Disadvantages:
- High energy consumption and long printing time; It was harder to control the first printing.
In the production according to the printing order demand and the actual situation of the printing machine to determine the specific method. According to the test of relevant personnel, after the adoption of the scheme, in the subsequent production, similar short plate printing order can save 6% of the total cost
Mark :Full plate printing is a type of printing in which a material is filled with a single color printing. For example choose one color as background to cover whole material roll surface .
