Carton printing machines are an essential part of the packaging industry, producing containers and boxes that protect and transport a wide range of goods. Understanding how these machines work is very important for businesses looking to optimize their packaging standard and efficiency. This guide provides a full overview of the step-by-step process involved in carton printing.
1. What is a carton printing machine?
A carton printing machine is a printing gadget that can print the required patterns, text, and other information on the surface of the box’s cartons. It generally contains process steps, such as ink coating, plate loading, and paper feeding and embossing. Carton printing generally contains a one printing machine, carton printing slotting/die-cutting machine, automatic high-speed flexo printer, and rotary die-cutter inline.
2. How do carton printing machines work?
The following is the working principle of a carton printing machine.
1) Prepares
The prepress stage involves preparing the artwork and design for printing. It starts with the creation of the real design, which is then converted into digital files using a graphic design program. Once the files are complete, they are sent to the prepress department, where they are checked for issues and optimized for the printing process.
2) Platemaking
Platemaking involves transferring the digital design to plates. These plates are generally made of metal or polymer and are coated with a photosensitive emulsion. The digital image is transferred to the emulsion using ultraviolet or laser light, creating a hardened image that will repel ink. The non-hardened areas, which represent the design, will accept ink.
3) Printing
In the printing stage, the printing plates are mounted on the printing area and inked. The board or paper is fed via the press, which presses the printing plates against the paper, moving the ink onto the surface. The ink is used in multiple passes, with each pass representing a different design color.
4) Drying
After printing, the ink must be dried to stop smudging and permit further processing. This is generally done using a series of ultraviolet lamps or heated rollers. The drying process varies depending on the ink type and the printing press speed.
5) Cutting and creasing
Once the ink is dry, the cartons are cut to the desired shape and image using a die-cutting machine. The die-cutting process also creates creases in the board, which permits the cartons to be folded into their end shape.
6) Gluing and folding
The end step involves gluing and folding the cartons. Glue is used on the flaps of the carton, which are generally folded and pressed combined to form the desired shape. The cartons are then left to dry and stabilize before being shipped and saved.
3. Advantages of carton printing machine
A carton printing machine can be a remarkable addition to any business that relies on cartons for shipping and packaging. Here are some of the advantages of carton printing machines:
1) Increased production speed
A carton printing machine can print cartons at a much quicker rate than a traditional printing press, raising your production efficiency and speed.
2) Durable results
Carton printing machines use high-standard inks that are designed to withstand the rigors of packaging and shipping. This means that your cartons will look remarkable and last longer, saving you money in the long run.
3) Customizable designs
With a box printing press and label machine printers, you can simply create custom designs that will stand out from the competition. You can also include your company logo or other branding elements in the cartons for an expert look.
4) Cost savings
Matched to traditional printing techniques, carton printer machines provide substantial cost savings. They get rid of the expenses linked with external printing services, material waste, and labor costs. Additionally, many carton printer machines are equipped with power-efficient specs, reducing operating expenses and promoting atmosphere sustainability.
5) Brand representation
These machines, like a flexo printing machine for corrugated cartons, help businesses maintain the best brand image. By producing high-standard print consistency, they contribute to full brand representation and make sure businesses make a lasting impression on their customers.
6) Scalability
Carton printing machines are very versatile and can accommodate a wide range of carton sizes and materials. They can handle both multi-pass and single-pass printing, providing producers with the flexibility to adapt to varying production requirements. Additionally, their modular design permits scalability, permitting businesses to upgrade or spread their printing capabilities as their needs evolve.
4. Disadvantages of carton printing machine
Here are some of the big advantages and disadvantages of carton printing machines:
1) High initial investment cost
Carton presses are costly pieces of equipment that can cost a lot of cash to buy and install. For little businesses on those or a restricted budget, this can be an obstacle.
2) Operating and maintenance expenses
Continue costs for machine consumables and maintenance such as cardboard or ink, may accumulate over time. Businesses must take these expenses into account to reject unexpected expenses.
3) Technical expertise requirements
Operating the carton printing machine needs technical expertise. Employees need to be trained to use the machine correctly and make sure it is best operation.
5. Installation of carton printing machine
The carton printing machine is a printing equipment that can print the required patterns, text, and other information on the surface of the carton box. Carton printing generally contains single printing, printing slotting, die-cutting, gluing boxes, and linkage production lines.
The carton printing machine can be roughly divided into a DC servo and gear drive by transmission. Most of the more and more largely used gear transmissions are now used.
The carton printer machine is usually composed of many units: printer unit, lead edge feeder, slotter unit, vibrator unit, die cutter unit, and stacker unit. The working principle of the carton printing machine is to first make the images and text to be printed into a printing plate and install it on the printing machine, and then run the printing machine to evenly apply the ink to the plates with the images and text on the printing plate, and then directly or indirectly transfer to the corrugated carton or corrugated paper to reproduce the same printed replica as the printing plate.
6. Maintenance tips for carton box printing machine
If you are in the business of carton box printing, then you know that your machines are a very important part of your operation. That is why it is so vital to take care of them and ensure they are forever in top condition. Here are the best maintenance tips to help you do just that:
1) Regularly clean the printing machine
Keep your machine clean. Regular cleaning will get rid of the build-up ink and waste, which can lead to clogs and other issues.
2) Schedule regular machine inspections
Check your machines regularly. Look for any signs of damage or wear, and ensure all moving parts are lubricated and working correctly.
3) Follow the maintenance schedule
Follow the producer maintenance schedule. This will make sure that your machine is getting the care it needs to stay up to date.
4) Be careful when moving the machines
Carton printing machines are delicate, so be alert when moving or lifting them around. Ensure to use the right lifting methods, and don’t try to move them by yourself if you are not confident you can perform so safely.
5) Keep standard replacement parts on hand
Invest in high-standard replacement parts. When it comes time to change parts, ensure you pick standard components that will fit rightly and last longer.
6) Store the machine in a dry, cool place
Store your machines correctly when not in use. Carton printing machines should be saved in a dry, cool, place to stop rust and other damage.
7) Schedule regular servicing
Have your machines serviced regularly. Carton printing machines are hard pieces of equipment, so it is vital to have them serviced by a professional technician on a regular basis. This will help make sure that they stay in the best working condition and last for many years.
7. Troubleshoot issues and how to solve it
Common quality issues and solutions in carton printing machines:
1) Bad adjustment of the pressure roller
Problem: The position of the press roller is too low or high, so that the contact with the corrugated cardboard is too loose or too tight, and there will be a bad version, a stale version or a partial imprint of the text and image.
Method: Adjust the pressure roller to a perfect position, so that the space between the pressure roller and the roller is compatible with the cardboard thickness, so as to make sure the location of the printing plate and reject the occurrence of this issue.
2) Defective parts connected to machine imprinting
Problem: When the plate roller shaft head, transmission shaft, impression roller shaft head, gears, and vital parts related to imprinting are loosened or worn, the plate roller or impression roller will jump during the imprinting process. Due to strange pressure, the printing plate surface and the cardboard are not in general contact resulting in the issue of partial or smearing imprinting of the cardboard printing surface.
3) Uneven thickness of corrugated cardboard
Problem: When the area of the formed corrugated cardboard is destroyed by human-made dents, the paper area of the dented part will also have standard defects with unclear imprints. If the printing force is increased in an all-around way to make up, it is simple to cause the standard issues of the text and line layout to be blurred.
Method: in order to avoid smearing the layout, the corrugated cardboard should be managed lightly, placed lightly, and lightly pressed during the handling and stacking process (the stacking height must be managed), and bad production habits such as smashing, throwing, and pressing should not be used for handling.
4) The inking roller is bad
Problem: When the inking roller shaft head is very loose, the inking roller body is deformed, bent, or the surface is destroyed, it will also cause the layout to be dirty, or the partial graphics are not very clear.
Method: Find out the cause; take related measures to deal with it, maintain uniform and right contact conditions between the printing plate and inking roller, and change the damaged inking roller in order to get rid of the malfunction.
5) Bad color order
Problem: if the graphics with a complete layout are arranged in the first color group for printing when the corrugated cardboard is printed in the next color group, the printing text and graphics of the first color group on the cardboard have a big amount of ink and a slow drying speed. It is simple to transfer the print and cause the layout to get bad.
Method: Arrange the little-area layout in the first color group for printing, and arrange the big-area layout in the subsequent color group for printing, which can reject the phenomenon of bad printing caused by imprint transfer.
8. Carton printing machine FAQs
The following are some common questions.
1) What is the principle of a carton printing machine?
When the carton printing machine is working, the images and text are printed on the printing plate, installed on the printing machine, and then the machine is run by a person, and the ink is evenly used to the image and text on the printing plate. Then indirectly or directly, the image is transferred to a carton to make the same printed copy as the printing plate.
2) What are the classifications of carton printing machines?
The carton printing machine has many types, which include printing slotting machines, printing machines, printing mold opening machines, linkage production lines, and so on.
9. Conclusion
Picking the best carton printing machine is the best investment that can elevate your packaging game and improve brand appeal. By carefully elevating your needs, exploring accessible types, and embracing technological advancements, you can find a machine that perfectly aligns with your special requirements.
We hope this guide has helped you understand the advantages of a carton printing machine. A carton box printing machine is a vital part of the carton box manufacturing process, so it is vital to pick the best printing technique for your needs.
