Carton Ink Flexo Technology: Common Problems and Precautions in Printing and Typesetting
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The layout process of corrugated boxes has long been a weak point in many companies' management systems, often overlooked or treated with little attention. However, the quality of typesetting directly affects the final print quality and production efficiency, making it a critical aspect that should not be neglected.
Many corrugated box manufacturers face common issues during the layout process. These include torn printing plates, misaligned adhesive tapes, and temperature fluctuations—especially in winter and summer—that cause the plates to age or deform over time. Such problems can lead to wasted materials, reprints, and reduced productivity.
To address these challenges, corrugated box companies must improve their storage and handling practices. Implementing 5S (Sort, Set in Order, Shine, Standardize, Sustain) is essential for maintaining an organized and efficient workspace. Printed versions should be stored in fixed locations based on usage frequency, and expired plates should be removed regularly. This ensures a clean, safe, and well-organized environment that supports smooth operations.
When setting up the hanging strips, it's crucial that the glue aligns precisely with the base edge of the plate. Traditionally, companies use adhesive tape to secure the hanging strip to the base, but this method can lead to shifting over time, especially in hot and humid seasons. To solve this, some manufacturers now use cold welding technology, which fuses the hanging strip to the base material without heat, ensuring a more stable and durable bond. Additionally, fiber tape is often applied at the ends of the hanging strip to prevent tearing under stress.
Accurate reference lines are fundamental to proper typesetting. If the initial drawing is off, it can result in layout errors, misalignment, or overprinting issues. There are two main reference lines: the vertical center line, which runs from the top to the bottom of the plate, and the horizontal zero line, which marks the standard distance from the edge of the corrugated box to the hanging film.
Once the reference lines are in place, the next step is to draw the upper shake line, box height line, and lower shake line according to the box dimensions. When marking, ensure that you follow the circumferential division requirements, but there’s no need to divide horizontally. During plate installation, always check for alignment, edge lifting, missing prints, loose adhesive, or damaged paper to avoid further complications.
Most corrugated box factories still rely on manual scribing, which often leads to significant positioning errors. Some companies have started using simple jigs or tools to locate each section accurately. These tools use projection techniques and directly print positioning lines onto the plate, significantly improving layout precision and consistency.