How to improve the adaptability of cigarettes on ultra-high speed packaging machines

At the morning meeting of our company one day, the Quality Control Department notified the production of the “Golden Leaf Jinmantang” small box of the cigarette packaging workshop of the manufacturing center: “ZB48 Super High Speed Packaging Machine of Baiban Zhengzhou Manufacturing Center was shut down five times due to the quality of packaging decoration. The Zhongbo Zhengzhou Manufacturing Center ZB48 super high-speed packaging machine was shut down four times due to the quality of packaging and decoration. Everyone started to discuss, "Is there a problem with the packaging machine?" "Is the friction coefficient of the cigarette package tested normally?" "Is there a problem with the indentation line?" "Is the quality inspection work done as required?". In the absence of discussion, the leader proposed that the quality control department take the lead in setting up an inspection team, and all departments coordinate and cooperate to find out the reasons at the production site and solve the problem as soon as possible. At the same time, after discussion, the paper also proposed the "ZB48 super high-speed packaging machine packaging adaptability research", set up a special technical team, and developed the ZB48 ultra-high speed packaging machine improvement measures and programs to improve its adaptability.Disposable Vape, Electronic Cigarettes, vape

Find the source of the problem

After 24 hours of on-site tracking and testing, the team members found the following problems with the quality of cigarette packaging and decoration.

(1) The on-site inspection value of the friction coefficient of the cigarette package is inconsistent with the factory inspection value of the finished product.

(2) The value of the indentation line parameter detection is unstable.

In response to the above two questions, the panel members reviewed a large amount of information, and analyzed the causes of the problems as summarized below.

(1) The stability and consistency of the friction coefficient of cigarette packages mainly depends on the glazing process. However, the glass transition temperature of varnish changes with the change of ambient temperature and humidity, which in turn causes the friction coefficient of the cigarette package to change. Moreover, during the glazing process of the cigarette package, the leveling property of the varnish is also unstable due to its own thixotropy and yield value, thereby causing a change in the friction coefficient.

(2) Under normal circumstances, since the indentation line detection of cigarette packaging is destructive detection, it can only rely on sampling inspection. If the pressure of the die-cutting machine is unstable during this process, the detection of the final cigarette indentation line is detected. The value will fluctuate. There are many reasons for the pressure instability of the die-cutting machine. For example, the die-cutting compensation method is not suitable. As the die-cutting machine runs for a long time and the temperature of the device rises, the offset paper is prone to misalignment or breakage. It is the direct cause of the abnormality of the height parameter of the die-cut indentation steel line.

Exploring solutions

In response to the reasons and problems analyzed at the production site, the team members conducted a brainstorming discussion and finalized the solution. The specific practices are summarized below.

(1) Inviting ink suppliers to participate in the improvement of the glass transition temperature characteristics of varnish, so that the Tg value meets the requirements of the environment temperature and humidity of the cigarette packaging production workshop .

(2) The detection environment before the packaging of the cigarette package on the machine is consistent with the cigarette packaging workshop.

(3) The friction coefficient and the indentation line parameter detection value of the cigarette package are reset by the benchmark method, and the viscosity parameter of the varnish is determined through experiments .

(4) to address the impact of thixotropy and yield value varnished its leveling property is, on the printing press increases the warming cycle apparatus varnish.

(5) Adjusting the die-cutting process, that is, pasting the die-cut film on the back side of the die-cutting die, and pasting the offset paper on the corresponding trace or knife line of the die-cut film, so that the die-cutting line is cut through and the indentation line reaches the standard, and Real-time monitoring of the change of die-cutting pressure during the operation of the die-cutting machine.

Trial production wins

According to the above solution, the team members made corresponding adjustments to the corresponding equipment and processes, and spent a total of nearly one month before and after, and then the test of the trial production. Waiting is long, and harvesting is joy. When the team members watched the cigarette package running smoothly on the “runway” of the ZB48 super high-speed packaging machine, 1 hour, 2 hours, 4 hours... the packaging machine operated smoothly, there was no downtime, and we were nervous. Relieve, the tears of joy come out.

I was dragging my tired body back home at 3 in the morning. I wanted to fall asleep and sleep, but my sense of mission and responsibility made me dare not close my eyes. I need to remember this precious day, add spiritual power to myself, and be alone under the blue light. Be prepared for the next step.

(1) Collecting and collecting data information of ZB48 super high-speed packaging machine on site for nearly one month, and establishing a new database for ZB48 super high-speed packaging machine.

(2) Combine the on-site tracking situation to compile the adaptive workflow and standards of ZB48 ultra-high speed packaging machine.

(3) Compile PPT courseware for die-cutting machine pressure training in combination with on-site tracking.

(4) Update the curing friction coefficient and the indentation line parameter standard.

(5) Improve the quality control topic - "Improve the applicability of the gold leaf gold full house small box decoration ZB48 packaging machine on the machine", in preparation for the 2016 China Quality Association QC project summary and conference.

Keep improving

In order to continue to promote the lean management work proposed by the company, the team members once again launched a fierce brainstorming on the topic of "ZB48 ultra-high-speed packaging machine packaging adaptability research", from "people, machine, material, law, ring, test" Start with a discussion on how to reduce production costs.

Hundreds of crickets contend, and those who fought are first. The panelists decided to improve the glazing process by reducing kerosene consumption. The status before the improvement is:

(1) The amount of the anilox roller varnish used in the printing machine was 9 g/m2.

(2) The anilox roller needs to be cleaned regularly during use, and the chemical cleaning agent used for cleaning will cause some erosion to the cells, causing damage to the cells.

(3) The mesh will have normal wear during the use of the anilox roller. As the use of the anilox roller changes, the mesh will become smaller and lighter.

After discussion, considering the problem of process improvement, the panelists decided to use an 8 gauge/aluminum anilox roll instead of an anilox roll with a coating weight of 9g/m2. The effect analysis was carried out by means of variance analysis. Related experiments, the experimental results are summarized as follows.

(1) The varnish was applied using an anilox roll having a coating amount of 9 g/m 2 and an anilox roll having a coating amount of 8 g/m 2 , and the value of the friction coefficient of the cigarette package was not significantly different.

(2) The use of an anilox roll having a coating amount of 8 g/m 2 can save 11% of the varnish coating amount.

(3) Test verification on the ZB48 high-speed packaging machine, the packaging speed is not affected, and the effect is very good.

Recalling this intense and challenging work for more than a month, I not only learned valuable practical experience, but also improved my personal ability, experienced the power of teamwork, and also received unexpected surprises – saving 11% of varnish costs. .

"The road is long and it’s a long way to go. I will go up and down." It is not terrible to encounter problems. As long as we cooperate sincerely, face up bravely, take the spirit and courage of rolling stones up the mountain, and work with the passion of the second venture, all difficulties can be overcome and all problems can be solved.

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