The packaging market is changing with each passing day. All types of packaging require flexible packaging companies to continuously improve and transform and innovate, especially individual fast-moving consumer packaging. In the past year or two, the mask packaging market has formed a very large demand for packaging, especially the fanaticism of online shopping, which has made the mask packaging incandescent.
The mask category has become a "fast-moving consumer product". More and more consumers are willing to pay for their convenience, fastness and beauty, and channel vendors such as terminal stores have also promoted the mask category as a focus, driven by the upstream and downstream of the industry chain. According to some data statistics, facial mask processors such as Jiebao and Beihao all claim that the production capacity needs to be increased by 50% to meet the continuous orders of all parties, and since 2012, new facial mask brands have emerged endlessly. According to relevant data, China's facial mask market is developing rapidly. In 2014, the market sales reached more than 11.5 billion, becoming the fourth largest category in the cosmetics industry after skin care, makeup, and skin care, and the market growth rate is much higher than other categories. .
The mask market is a very big cake, and it is getting bigger and bigger. Of course, it is a good thing for soft pack companies. The following introduces the main points of the production process of film packaging.
First, the characteristics and structure of the mask bag
Today's high-end facial masks have become a trend. In addition to showing excellent performance and texture on aluminum foil packaging bags , there is also a shelf life. Most masks have a shelf life of more than 12 months, and some even 36 months. With such a long shelf life, the most basic requirements for packaging are: tightness and high barrier properties.
In view of the consumption characteristics of the mask itself and its shelf life requirements, the material structure and requirements of the mask packaging bag are basically determined.
At present, the main structures of most masks are: PET / AL / PE, PET / AL / PET / PE, PET / VMPET / PE, BOPP / VMPET / PE, BOPP / AL / PE, MAT-OPP / VMPET / PE, MAT-OPP / AL / PE, etc.
From the perspective of the main material structure, aluminized film and pure aluminum film are basically used in the packaging structure.
Compared with aluminization, pure aluminum has a good metallic texture, silvery white, and has anti-gloss properties; aluminum metal has soft characteristics, and products of different composite materials and thicknesses can be customized according to requirements. Get a more intuitive manifestation from the packaging.
Because of this, the basic functional requirements of the mask packaging bag from the beginning to the high-end requirements of performance and texture are rising simultaneously, which has contributed to the transformation of the mask bag from aluminized bag to pure aluminum bag.
It is self-evident how important the mask packaging bag is to the mask. Compared with the fancy decorative effect on the surface, the storage and protection function of the packaging bag is actually more important. But in fact, many people ignore the problem and ignore it.
From the analysis of the raw materials themselves, the general mask packaging bags are mainly divided into two types: aluminized bags and pure aluminum bags. The aluminum-plated bag is a high-temperature vacuum state, uniformly coating high-purity metal aluminum on a plastic film. Pure aluminum bag is made of pure metal aluminum sheet and compounded with plastic film, which can improve the functions of plastic's barrier properties, sealing properties, fragrance retention, shielding properties, etc. That is to say, the pure aluminum mask bag is more suitable for the market requirements of the current film packaging bag.
Second, the main points of production control of mask packaging bags
From the current market requirements and consumer perspective, masks are basically regarded as high-end products, so the most basic decoration requirements are different from ordinary food and daily-use packaging requirements, at least it is a "tall" Consumer psychology. So for printing, taking PET printing as an example, its overprint accuracy and hue requirements are at least one level higher than other packaging requirements. If the national standard standard is the main overprint accuracy of 0.2mm, then the secondary position of the mask packaging bag printing basically needs to meet this printing standard in order to better meet customer requirements and consumer needs.
In terms of chromatic aberration, customers of mask packaging are stricter and more detailed than ordinary food companies.
Therefore, in the printing link, for overprinting and hue, companies producing mask packaging should pay attention to control. Of course, for printed substrates, there are also higher requirements to meet the high requirements of printing standards.
Compounding mainly controls three major aspects: compound wrinkling, compound solvent residues, compound pitting and bubbles. In this process, these three aspects are the key factors affecting the yield of mask packaging bags.
(1) Composite wrinkling
As can be seen from the above structure, the mask packaging bag mainly involves the compounding of pure aluminum. Pure aluminum is rolled from pure metal into a very thin film-like sheet, which is commonly known as "aluminum film" in the industry. The basic thickness is between 6.5 ~ 7μm. Of course, there are also thicker aluminum films.
Pure aluminum film is very prone to wrinkle or material breakage, or abnormalities such as tunnels during the lamination process. Especially for the automatic compounding machine, when receiving the material, due to the irregularity of the automatic bonding of the paper core, it is easy to be uneven, and it is very easy for the aluminum film to be directly wrinkled or even dead wrinkled.
For the wrinkled material, we can remedy it on the one hand to reduce the loss caused by the wrinkled material. When the composite glue is stabilized to a certain state, it is a way to re-roll it, but this is only a way to reduce it; on the other hand, it can go from the source. Reduce, such as the use of a larger paper core, make the winding effect more ideal.
(2) Residual solvent
Since the mask packaging basically contains aluminized or pure aluminum, for the composite, the presence of aluminized or pure aluminum is disadvantageous for the volatilization of the solvent, because the barrier properties of the two are stronger than other general materials, so It is not good for solvent evaporation. Although it is clearly stated in GB / T10004-2008 "Packaging plastic composite film, bag dry composite extrusion compounding" standard: This standard does not apply to plastic films and bags made of plastic materials and paper-based or aluminum foil composites.
However, the current mask packaging companies and most companies also take the national standard as the standard. For aluminum foil bags, they also follow the requirements of this standard, which has caused some misleading.
Of course, there is no clear requirement for the national standard, but we still have to control solvent residues in actual production. After all, this is a very critical control point.
As far as personal experience is concerned, it is feasible to make effective improvements in terms of glue selection and production machine speed, oven temperature, and equipment exhaust volume. Of course, this aspect requires analysis and improvement of specific equipment and environments.
(3) Composite pits, bubbles
This problem is also mainly related to pure aluminum, especially when the structure of composite PET / AL is easier to show. The composite surface will accumulate a lot of "crystal point" -like phenomena, or similar to the "bubble" point-like phenomenon, mainly due to several reasons:
In terms of substrate: the surface treatment of the substrate is not good, and pitting and bubbles are easy to occur; too many and too large crystal points of the substrate PE are also a major cause of problems. On the other hand, the particle aspect of the ink is also one of the factors. Also, the leveling of the glue and the coarser particles of the ink will also cause similar problems during bonding.
Moreover, when the machine is operated, when the solvent is not evaporated enough and the compound pressure is not large enough, a similar phenomenon will also occur, or the gluing wire roller is blocked, or it is a foreign matter.
Look for better solutions from the above aspects, and make targeted judgments or exclusions.
At the control point of the finished product process, the flatness of the bag, the strength of the edge seal, and the appearance are mainly considered.
In the bag making process, flatness and appearance are difficult to grasp. Because its final technical level is determined by machine operation, equipment, and operating habits of employees, the bag is very easy to scratch in the finished product process, and there are abnormalities such as large and small edges.
For mask bags with strict requirements, these are definitely not allowed. In view of this problem, we may wish to manage the machine from the most basic 5S aspects to control the phenomenon of scratching.
As the most basic workshop environmental management, the machine cleaning involved is one of the guarantees that the machine is tidy and free of foreign objects on the machine to ensure normal and smooth work. This is a basic production guarantee. Of course, it is necessary to change to the most basic and specific operation requirements of the machine.
In terms of appearance, the requirements for edge banding and the strength of edge banding are generally required to apply a finer texture, or even a flat sealing knife to press the edge banding. This is a relatively special requirement. It is also a great test for the operators of the machine.
4. Selection of substrate and auxiliary materials
The PE used in the mask needs to select functional PE materials that are resistant to stains, liquids and acids. From the perspective of consumer habits, PE materials also need to be easily tearable. For the appearance requirements of PE itself, crystals Point is its key production control point, otherwise many abnormalities will occur in our compounding process.
The liquid of the mask basically contains a certain percentage of alcohols or alcohols, so the glue we choose needs to use a medium-resistant glue.
Third, the conclusion
In general, during the production process of the mask packaging bag, many details need to be paid attention to, because its requirements are different and the loss rate of the soft bag company will be relatively high. Therefore, the details of each of our process operations must be very meticulous and improve the yield to be able to stand on the commanding heights in the market competition of such packaging.