Standardization and dataization have become essential in improving production efficiency, quality control, and technical management in corrugated box factories. Traditional management methods can no longer keep up with the demands of modern manufacturing. As a result, most corrugated box factories are now focusing on standardizing and digitizing their processes, aiming to create more consistent and reliable operations. However, the data from each stage is often isolated or processed in parallel, which limits its ability to guide production and technological improvements effectively. The author believes that process data should be integrated vertically, enabling managers and technicians to better understand the root causes of issues, thereby enhancing control over production, quality, and process optimization, ultimately leading to higher customer satisfaction.
The production process for watermark corrugated boxes typically involves three layers of cardboard produced on a corrugation line, followed by direct ink printing, round die cutting, box assembly, and final inspection.
Comprehensive data collection and meticulous management throughout the entire production cycle of these boxes lay the foundation for product quality and usability. Therefore, it is crucial to monitor key data at every stage so that analysis can be conducted systematically. This article presents a series of data analyses from a specific phase in the production of watermark corrugated boxes.
As seasons and time periods change, the production conditions of the watermark corrugated boxes also vary. At this stage, the environmental conditions were: temperature between 20°C and 30°C, relative humidity ranging from 30% to 50%, steam pressure on the corrugation line between 7 and 8 atmospheres, drying belt temperature between 110°C and 130°C, and the production speed of the corrugated board line was between 90 and 100 meters per minute.
In the watermarking stage, the longer the three-layer cardboard was stored before printing, the lower the surface temperature of the whiteboard paper when the board was printed. Once the surface temperature of the cardboard reaches equilibrium with the ambient temperature, further storage does not significantly affect the temperature. As shown in Figure 1, the first three batches of cardboard had a storage period of 36 hours, resulting in surface temperatures between 22°C and 28°C. For batches 4–11 and 17–18, the storage time was 16–20 hours, with surface temperatures ranging from 22°C to 30°C. In contrast, batches 12–16 had a shorter storage time of 8–10 hours, leading to higher surface temperatures of 30°C to 42°C.
Analysis of the printing pressure data in the watermarking section revealed that both the storage duration and surface temperature of the cardboard could influence the ink printing process. Figure 2 shows the printing gap curves for different color groups when printing various batches of cardboard. A smaller printing gap value indicates higher printing pressure.
From Figure 2, we can see that the first three batches of cardboard had a longer storage period, allowing the moisture and surface temperature to stabilize. This increased the stiffness of the cardboard, resulting in lower printing pressure and a printing gap value greater than 2.2 mm. The printing gap values for batches 4–11 and 17–18 were above 2 mm. However, the worst performance was observed in batches 12–16, where the printing gap was less than 1.8 mm, indicating excessive pressure and potential damage to the print quality.
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