Planning: " Guangdong Packaging " Editorial Department
Writing: Fan Junhong, Shen Xiaoyun
Date of writing: October to November 2013
Solvent-free compounding has developed in a blowout manner in the past year or two. Many companies have not purchased the first solvent-free equipment for a long time, and quickly purchased the second one. However, there are also reactions from enterprises. Although they can basically produce normally, there are still many small problems of this kind.
Now we will introduce the use status of some enterprises we have learned for everyone to understand this process more intuitively.
I. Views of high startup rates and the successful use of solvent-free companies
1. General Manager of Harbin Botai Chen Wanxiang
Status of use: At present, there are two Tongze solvent-free equipment, which were put into operation in October 2012 (1.3m width) and September 2013 (width 1.1m, there are 2 stations for unwinding, which can be used for aluminum foil and Yinyang membrane). At that time, the purchase of solvent-free was mainly based on the two ideas of reducing costs and improving efficiency. At present, the two devices are operating normally and the startup rate is high. Generally, they are opened from 7:00 am to 10:00 pm. The main composite products It is seeds and rice packaging that account for 80% of the order. The rest are fertilizer packaging (fertilizers are powder and granules) and pesticide packaging. Rice packaging generally adopts PA // PE structure, and the startup speed is 200 ~ 250m / min. Chemical fertilizer packaging uses PET. // PE or OPP // VMPET // PE (the three-layer compound of this structure is solvent-free). The pesticide packaging structure is: PET // VMPET // PE, but the outer layer is still dry compound, and the inner layer is solvent-free. Compound, the sizing amount is 1.5g / m2. The glue used is Bost gum and Kangda gum.
1. When solvent-free was first used, composite aluminum coating products were prone to aluminum transfer and white spots, but now this problem has been basically solved.
2. Solvent-free glue will consume the slip agent of PE film, which will increase the friction coefficient and cause poor opening of subsequent bag making.
Experience in use: There are more than 1,000 customers, many orders are very small, and sometimes 4,000 to 5,000 orders are made without solvents. The key is to buy more rubber rollers for backup. Our company has 60 rubber rollers. Convenient and fast, you can change it in 5 minutes. Our company has saved a lot of costs by using solvent-free. However, there have been some problems in the early stage of use. We have constantly summarized and explored it, and we have paid great attention to the management of production processes. Now it is used smoothly. In the past, there were 12 people in the compound workshop, and now there are 2 solvent-free compounds. Only 5 workers are needed, which greatly saves labor costs, and the delivery time is shortened from 25 days to 10-12 days. Enterprises must make good use of solvent-free must not be anxious, do not rush to achieve success, do not blindly pursue speed. Be sure to do a small test. We opened the solvent-free system, which also slowly increased from 100m to 120m and then increased to 150m and 200m. Stabilize and drive fast, so you can avoid losses.
Development trend: The key is to determine the future development of solvent-free based on the structure of the product. I am personally optimistic about solvent-free. At present, the company has only one dry-duplex machine, and the startup rate is not as high as that of solvent-free. Turn on and off again. Solvent-free is the predominant, and the dry process becomes the auxiliary process.
2.Mr. Tan, Shunde Fine Printing & Packaging Co., Ltd.
Compound status quo:
In September 2012, the first Nordmec solventless laminating machine purchased by Jingyin based on power saving purposes was put into production, which not only successfully solved the problem of power shortage of Jingyin, but also changed the version faster than dry lamination, and greatly Reduced labor intensity for employees. In the composite process, there are no common composite quality problems such as tunnels and white spots. Jingyin soon purchased two more solvent-free composite equipment. The three solvent-free composite machines can be turned on for more than 20 hours a day, the speed can be up to 350m / min, and the stability is very good, which can save energy consumption by about 50%. In September 2013, Jingyin purchased two more solvent-free equipment from Nordec. The fourth equipment was delivered at the end of September and the fifth was delivered in October.
At present, the composite product structure is basically an opp / pearlescent film or OPP / aluminum, which is a relatively simple structure. Products with special requirements such as high temperature cooking and acid and alkali resistance have not been compounded using solvents.
Solvent-free energy-saving, environmental protection, safety, high efficiency, save money, and solvent-free composite equipment, glue and technology are constantly maturing, more and more companies can use solvent-free good, I believe that solvent-free composite will develop faster. However, when using a solvent-free enterprise, it is best to first compound products with simple structures, wait for employees to accumulate certain operating experience, and then start experimenting with special structures.
3. Vice President of a color printing company in Foshan
Status of use: Nodmark's equipment was purchased in June 2000, at the time it was the 16th device sold by Nodmark in China. Reasons for purchase: 1. Based on orders and customer needs; 2. Energy-saving, environmentally friendly, safe, and money-saving process without solvent; 3. The company itself also pays attention to the use of environmentally friendly processes. It chose alcohol-soluble ink 15 years ago. Green technologies are willing to try, which is also the market development trend. The company mainly provides packaging for large food companies, such as Green Arrow. The main composite products are paper plastic products, paper / PET. These products have high environmental humidity requirements, and process control is a bit difficult. High glue, now also using Guowang glue, their glue price is low, and the quality is very stable. Now also use ordinary solvent-free composite plastic products, such as OPP // CPP, BOPP // pearl film (gluing amount of 1.2 ~ 1.3g), the use of Fuller two-component glue, they serve very well. Because there are more composite products, the equipment startup rate is now much higher than the original. Basically 8 to 10 hours of daily startup, the daily glue consumption is about 25kg.
1. The problem of controlling the amount of glue and tension control. It is critical to adjust the tension of two materials with completely different properties, paper and plastic. There is also a poor adjustment of the guide rollers and pressure rollers, which will also affect the composite quality.
2. The appearance of individual solvent-free composites will be inferior to that of dry compound, and customers are more concerned about appearance.
3. The product's initial tack is low, and it is impossible to grasp the composite quality, which sometimes affects the enthusiasm of the enterprise.
When the solvent-free equipment was first started, the startup rate was not too high due to product structure and process problems. Since 2011, the scope of use of solvent-free has been expanded. After using ordinary two-component plastics to make common plastic products, the startup rate has been greatly improved. rate. The solvent-free process attaches great importance to the installation environment and the constant temperature and humidity environment, which is also related to the composite quality of the product.
Development trend: With the continuous development of technology and the advancement of glue technology, ordinary cooking and special function packaging can also be made without solvents. Fuller's products with high curing rates can greatly shorten the curing time, which plays a key role in promoting the development of solvent-free. Solvent-free future market share will definitely increase significantly, but it will not replace dry lamination.
4. Mr. Li, a plastic packaging company in Shenyang
Status of use: In September 2010, Tongze equipment with a mechanical speed of 350m / min was purchased. The main products are seed packaging, pesticide packaging, and rice packaging. There are more than 200 customers. Small orders of 3 kilometers and 6 kilometers are used. Solvent-free, and the product is mainly repacked. The product structure is PA // PE, (the gluing amount is 1.5g / m2, the previous dry compounding required 2.5g / m2, the startup speed is 300m / min), OPP // VMPET // PE or PA // VMPET // PE, etc., the current equipment startup rate is very high, basically open 24 hours, the glue used is European and American chemical glue (the glue is very stable, cost-effective).
1. The maturation time is too long, and some products need 4 to 5 days to fully cure. If heated, it will increase the friction coefficient.
2. It is mainly difficult to grasp the tension control, because there is no initial adhesion, so if the control is not good, wrinkles, tunnels, blistering, and tension mismatch problems will occur.
3. The difficulty of compound PA is large, and the problem of compound strength is easy to occur.
The solvent-free requirements on the substrate are very strict, it must be very flat, and the environmental requirements are to achieve constant temperature and humidity conditions. When I bought back the solvent-free equipment, I experienced a lesson of failure and caused a loss of 20,000 yuan in the first month. The reason was that the operator was unfamiliar with the process, and there were problems with the equipment's tension control system and online detection. . After a period of exploration and research on the process, the equipment is now running stably and the startup rate is very high. We made money on the equipment in a year. In the past few years of use, my most profound experience is: to use solvent-free, there must be a good management system, highly responsible workers, monitor the amount of glue at any time, operate and use strictly in accordance with the requirements of processes and processes, When trying new structures, you must make a sample first. Common white spots and openness problems can be overcome. If the management of an enterprise is not good, it is recommended not to use solvent-free.
At present, there are 2 dry-duplex machines, but the start-up rate is not as high as solvent-free. Next year, a dry-duplex machine will be phased out and a solvent-free machine will be installed. The country's increasing emphasis on environmental protection and safety, the development of solvent-free will inevitably become the mainstream process of flexible packaging .
5. Manager Chai Hongshun of Hebei Xinghai Packaging Co., Ltd.
Status of use: At present, there are two solvent-free equipments, namely Yuncheng Nanguang and 1.3m wide Nordmec equipment. The reason for the purchase was mainly because of the low cost of solvent-free use. I bought one with a trial and error attitude and indeed saved costs, so I bought the second one. The company's main products are food packaging with a structure of BOPP // VMCPP (gluing volume of 1.5 ~ 2g / m2 and startup speed of 150 ~ 200m / min), and PET // PE (gluing quantity of 1g / m2) , PET // OPP, these structures are large and large orders. The equipment startup rate is about 12 hours per day. The glue currently used is Henkel and Kangda's glue, and the monthly glue consumption is about ten tons.
1. BOPP / VMCPP structure has slow production speed and high glue volume. The production speed is 150m / min, the glue volume is above 2g / m2, the quality can be stable, otherwise white spots are easy to appear.
2. The BOPP / PE product rolls out the tunnel up to 20 meters, the tension adjustment is invalid.
3. Local labeling products, compound BOPP / VMPET structure, high thickness at the labeling place, and black marks at the vertical labeling place after rewinding.
4. Compound MAT-BOPP // paper-plastic products, using a single-component adhesive, serious air bubbles when going down. The metering and transfer roller temperature is 80 ℃, the compound temperature is 30 ~ 50 ℃, the tension adjustment is invalid, and the vehicle speed is 50 ~ 200m / min.
5. The composite BOPP // VMCPP structure product roll core has severe ink scratches at 30 ~ 50m, accounting for about 30% ~ 90%.
When there is a problem in use, the equipment and the glue factory's service follow-up is insufficient, and the domestic rubber rollers have been used for a long time, which will cause stagnation, which will cause some trouble to our use.
Although there are some process problems in use, it is very optimistic about the future development trend of solvent-free, and it will inevitably replace some dry compounding and become the mainstream compounding process.
6.Technical Manager of Fujian Kaida Group
Status of use: At present, there are three solvent-free equipment, which are Tongze equipment purchased in May 2010, and two Nordmec equipment purchased in November 2010 and December 2011. The key reason for no solvent at that time was that it could avoid the problem of solvent residues, and the second reason was to consider the advantages of energy saving and money saving. 90% of the company is food packaging, 10% is daily chemical packaging, conventional structure is done, including OPP // CPP, PET // CPP, PA // CPP, BOPP // VMCPP, PA // PE and other products, generally start The speed goes to 300m / min, the minimum speed is 250m, mainly depending on the product structure. The three machines are operating normally. The monthly startup rate is 26 days. The three machines share about 30 tons of glue each month. Gum, Dow and Conda.
1. Poor appearance, with air bubbles, white spots, wrinkles, low peel strength, and increased friction coefficient.
2. Low initial tack, long curing time, difficult to match glue and ink, especially alcohol ester ink and solvent-free glue are prone to stickiness.
If the equipment does not have a dual station device, it is not convenient to operate when switching materials. The most worrying is that the glue mixing system and alarm device are malfunctioning. Tongze's glue mixing system is better than imported brands. What is missing is that it is not visible on the operation display Glue volume ratio and weight ratio. High-temperature cooking packaging is not too mature at present, mainly because the performance of glue needs to be further improved.
I am very optimistic about the development of this process because of environmental protection, low energy consumption, and cost advantages, which can save about 50% than dry compound. As the technology matures in the future, it may account for 50% of the market share, but the specific time is not accurate.
7. Manager of Shanxi Xinhongyuan Color Printing Ma Hongping
Status of use: In September 2011, Tongze's solvent-free equipment was put into production, mainly based on the consideration of saving money. The company mainly focuses on food packaging. The composite structure includes OPP // CPP (gluing amount is 0.8g / m2, booting speed is 350m / min), PET // CPP (gluing amount is 0.8 ~ 1g, booting speed is 300m / min), PA / / CPP, PET // VMCPP, BOPP // VMCPP, PA // PE The amount of glue on these structures is basically controlled at 1.2 ~ 1.3g, the startup speed is generally 300 m / min, the startup rate is high, and the startup is more than 10 hours a day , Business for a long time, start up 24 hours, the monthly glue consumption is about 2 tons, mainly using Kangda glue.
Matte film // WMPET, with a startup speed of 200 meters, white spots are always prone to occur. White ink is used for alcohol, which can occur at high speeds and low speeds.
Experience in use: From the aspect of cost saving, there are certain advantages, but the composite aluminum plating film will undergo aluminum plating transfer, resulting in white spots, and process control is a bit difficult.
Development trend: I am still optimistic about the development of solvent-free processes.
8. Manager of a Hunan Packaging Product Co., Ltd.
Status of use: At the end of 2012, Tongze equipment was purchased, mainly based on the consideration of solvent-free energy saving and money saving. We are 100% food packaging. The main products are mainly OPP // CPP, the gluing amount is 1.5 g / m2, the startup speed is generally 300m / min, and some product structures are PET (OPP) // paper, monthly The startup rate is about 20 days, and the amount of glue used every month is more than 2 tons. Kangda's glue is mainly used, and a small part is Wuhan Fangcheng glue. Our current order is not too much, mainly using solvent-free composite large products, small orders do not need to do without solvent.
There are no major problems, and occasionally there are minor problems, such as minor faults on the equipment, and the belt is broken once.
Experience in use: Because our product has a simple structure, and no solvent is used for large orders, it is very smooth to use. Basically no problem.
Development trend: Solvent-free must ensure stable quality before it can develop into mainstream technology. I personally have full confidence in solvent-free.
9. Technical manager of a large soft package company in Henan
Status of use : At present, there are 7 solvent-free production lines, which are mainly used for meat product packaging. Among them, 5 are Nordmec equipment and two are Rodmac equipment. The product structure has OPP // PVDC // PE, PA // PE, PET // PE, OPP // CPP and other structures. Among them, it is used for low temperature corn sausage. The main structure is OPP // PVDC // PE. All three layers are used. Solvent-free process, it takes 48 hours to mature, fully achieve the dry compound effect, saving 40% than the dry compound cost. High temperature cooking structure resistant to 121 ℃. For example, OPP // PVDC // PP has been made in small batches in a solvent-free process, and the quality is acceptable. The equipment is currently operating at full capacity, using tens of tons of glue per month, mainly using Henkel and Cromo glue.
Use problems: mainly the problem of peeling force, and the problem of crystal point reduction and film transparency after compounding. PA // PE is inferior to dry compounding, and high temperature resistance is not as good as dry compounding.
Experience in use: Solvent-free is best used in large-scale factories. Large orders made in batches will have fewer problems, and the two advantages of high efficiency and money saving will be brought into full play. At present, the solvent-free process has yet to be further developed and matured. The main reason is that the performance of the glue must be adapted to different product structures, and it must be very stable before it can dispel some enterprises' concerns and concerns.
Development trend: It will become the mainstream technology, and it is completely possible to occupy 30% of the soft bag compound market in the future.
10, Hunan Xiangwei packaging Fu Xingshi solvent-free captain
Status of use: Based on energy-saving and product structure considerations suitable for solvent-free processes. I purchased Tongze equipment at the end of 2008, and this year I bought another Nordmec equipment. At the end of the year there will be a domestic line. The product structure includes OPP // CPP, sizing amount is 1.2 ~ 1.8g, startup speed is 250m / min, PET // CPP, PET // VMCPP, BOPP // VMCPP, VMPET // PE, AL // CPP, etc., There were some problems at the beginning, but now there are improvements. There is a 25-day startup rate every month. The main use of Bostik is.
Use problems: When the first line is first started, the coating roller of the equipment will jump, causing uneven gluing and problems with the coupling, and some small mechanical failures will affect normal use. After a period of debugging and running-in of the Tongze equipment, the machine is now slowly operating. I heard that the current Tongze equipment has been greatly improved.
Experience in use: At the time, you should go to the dual-station configuration, which can greatly improve efficiency. When I first used it, there were a lot of problems. Now I have adapted one by one and basically solved it.
Development trend: We are optimistic about the development of solvent-free, which will definitely become the mainstream process. We have already entered 2 lines, and we must go to the third line.
11.Xu Changyuan Color Printing Manager Wu Yongfeng
Status of use: Based on energy saving, saving money, etc., I bought Tongze equipment in 2011, mainly for food packaging. The structure includes: OPP // CPP, sizing amount is 1.1 ~ 1.2g / m2, BOPP // VMCPP. The glue volume is 1.4 ~ 1.5 g / m2, and the monthly startup rate is about 20 days. The used glues include Kangda, European and American Chemicals, and Gao Meng. The monthly glue usage is about 2 ~ 3 tons.
1.The composite aluminum plating film is prone to produce white spots;
2, irregular bubbles;
3. Matching of ink and glue
Experience in use: The solvent-free process has yet to be explored. I feel that high-quality compounding is difficult to achieve, and I am deeply troubled by the matching of ink and glue.
Different composite processes have their own application fields. Solvent-free processes will increase slightly, but dry composites are still the mainstay.
12, Zhao Zhongmin, general manager of Henan Hebi Zhongzhou Color Printing Co., Ltd.
Status of use: Based on considerations of efficiency and cost, I bought Tongze equipment in July 2013, mainly for food packaging, with many product structures, including OPP // CPP, PET // CPP, PA // CPP, PET // VMCPP , BOPP // VMCPP, PA // PE, VMPET // PE, the amount of glue is different depending on the structure, generally 1.1 ~ 1.8g / m2, the machine speed is generally 350m / min, the startup rate is about 20 hours per day, Kangda glue is mainly used, and the monthly glue consumption is about 2 ~ 3 tons.
There is basically no problem, and there are very few waste products. Workers' operations are very standard. Unlike the dry-duplication, Tongze's training is also in place, focusing on the entire work process. However, there are some problems that should be paid attention to in solvent-free processes: for example, cooking glue and general-purpose glue cannot be used together, they must be cleaned, rigid materials, and the quality of two-layer materials with good barrier properties is difficult to control, such as PET // AL, PET / / VMPET.
Experience in use: The solvent-free process has only been developed in China for a few years. The time is not long, and the theoretical standards and actual operations are too different. For example, the curing time and temperature control of the gum, some structures, theoretically requires curing at a temperature of 40 ~ 45 ℃ for 24 hours, but some of our products can be cured for 6 hours, sometimes at 30 ℃, 10 hours is OK Already. So the key is to summarize and explore by yourself.
I think the solvent-free process will become popular within 2 years, and it will be inevitable to become a mainstream process.
13. Technical manager of a packaging factory in Wuhan
Status of use: In 2010, I bought a Nordmark equipment. The company mainly makes food packaging. The main structure is PA // PE. The gluing amount is 1.2 ~ 1.5g / m2, the startup speed is 200m / min, and the rest of the structure. For: PET // PE, OPP // CPP, the average start-up rate is about 8 hours per day, and the monthly glue consumption is about 1 ton. The main use is Bostik.
Use problems: The current use is relatively stable, and no major problems have occurred. It is considered that the bottleneck of the solvent-free process is that the problem of aluminum permeation at the bottom of the winding is a difficult point.
Experience in use: The reason why the current solvent-free start-up rate is not too high is that the main product structure is PET // AL // PA // RCPP high-temperature pure aluminum products, and the inner layer PA // RCPP solvent-free composite has no problem at all It ’s not good to try a lot of glue in the outer layer. Now try the Fuller glue, it is generally OK, but the quality is unstable, mainly in terms of compound strength.
Development trend: In recent years, it is obviously felt that the development speed is very fast, and it should become the mainstream process.
14. Xu Jia, general manager of Henan Luohe Biyou Special Printing Co., Ltd.
Status of use: Two sets of Tongze equipment were purchased in 2011 and 2012. The main products are food packaging and many structures, including OPP // CPP (gluing amount is about 1 ~ 1.3 g / m2, startup speed is 300m / min, PET // CPP, sizing amount is 1.7 g / m2, startup speed is 200 ~ 300m / min, and other structures include PET // VMCPP, BOPP // VMCPP, PA // PE, VMPET // PE, AL // CPP, etc. , The boot rate is very high, basically open 24 hours a day, used Henkel and New Oriental rubber.
Use problems: Basically OK, not many problems.
Experience in use: I purchased solvent-free equipment based on cost, energy saving, and high efficiency, and achieved the goal in practical applications.
Development trend: It will gradually become the mainstream process.
15. Liu Wenjing of Sichuan Paul Packaging Co., Ltd .:
Compound status quo :
My company purchased a Nordmek solvent-free laminating machine. Purchased in September 2012. The main reason for the original purchase was that the production cost could not come down, and the energy consumption was large, so it was considered to be able to do some lightweight packaging. At present, there is almost daily work. Mainly for BOPP / CPP, BOPP / PE, BOPP / VMCPP and other structures. For packaging of snack foods below 100g / bag.
We use Rohm and Haas solvent-free adhesives.
Problems currently encountered:
The control of the amount of glue per unit area is not easy to solve. Need to adjust the gap control frequently. Solvent-free adhesives will affect the smoothness of the film and hope to solve them.
Experience in use: Solvent-free is most suitable for composite two-layer structure without aluminum foil. I think the current bottleneck is: the introduction and operation proficiency of non-stop refueling equipment. Then there is the solution of the initial adhesion.
Future development trends: Solvent-free will definitely become the mainstream in the future. As long as the cooking compound and aluminum-plastic compound are solved, this will be accepted by all manufacturers. It is also a new environment-friendly industry.
16. Dalian Dafu Plastic Color Printing Co., Ltd. Wu Xiaojun:
Compound status quo:
Dafu solvent-free laminating machine is a Nordmec equipment from Italy; the equipment was introduced in 1996 (the first in mainland China and three in the same period). The main reasons for the introduction of equipment are the safety and health requirements of products (specific products) and environmental protection requirements. At present, the operating rate of the equipment is very high. Basically, people are idle for 24 hours. The equipment is mainly used for two-layer packaging structure of ordinary dry goods (below boiling level). Almost all imported solvent-free adhesive brands have used (Rohm and Haas, Henkel, Cromo, Bostik, Keyi, Huntsman, etc.), but have not used domestic brands.
Problems currently encountered:
The main problems encountered and solved: the compatibility of adhesives with inks of different systems and the appearance of aluminized structures.
Experience in use: the most suitable structure without solvent: simple two-layer plastic structure. At present, the main process bottlenecks of solvent-free compounding in China are: poor initial viscosity, guarantee of printing appearance of aluminized structure, and use of cooking structure.
Now solvent-free adhesives are becoming more and more perfect, and many large companies have begun commercial production of cooking-grade products; domestic solvent-free related industries are also gradually improving, and domestic equipment and adhesive manufacturers are also developing; In 2012, domestic flexible packaging companies paid more and more attention to solvent-free compounding. In recent years, more and more solvent-free equipment has been put into production in China; domestic awareness of safety and environmental protection has become higher and higher; solvent-free compounding is gradually becoming one of the mainstream compounding methods.
17. General Manager of Shanxi Pengyuan Color Printing:
Compound status quo:
The brand of our company's solvent-free equipment is: Guangzhou Tongze. The purchase time was September 2012. The reason for the purchase is that the solvent-free equipment has no drying process, has a small amount of glue, and has a fast speed, which saves a lot of cost than dry compounding. At present, the equipment is under full load production. The main composite structures are NY / PE, BOPP / CPP, which are used for washing powder packaging and food roll packaging. The glue brand used is: Shanghai Kangda.
Problems currently encountered:
1. Bubbles and wrinkles have been resolved by groping. 2. There is a phenomenon of glue-eating PE slip agent in the solvent-free compound, which is more serious. The friction coefficient increases when the thinner coils are compounded, which cannot be used on the automatic packaging machine. It has not been resolved yet. 3. Glue is relatively easy to dry. The compound roller has to be cleaned for 70,000 meters, but it is not solved.
Solvent-free is most suitable for composite structures: BOPP / CPP, lightweight coil packaging. Current process bottlenecks: aluminum foil, cooking and repacking are not possible, and three or more layers of compounding must be cured before being compounded again, which is troublesome.
The applicability of solvent-free is now very wide. From our perspective and local counterparts, it has become the mainstream composite method.
18. Zhou Lili of Huangshan Yongxin Co., Ltd .:
Compound status quo:
We purchased imported solvent-free composite equipment in 2007. At that time, we complied with the requirements of national policies to make our products as environmentally friendly, safe, and hygienic as possible, so that there were no solvent residues. At present, we have five solvent-free composite equipments, and the solvent-free composite startup rate is 100%. The two-layer and three-layer structures are mainly compounded. The two-layer composite is mostly used in food packaging, paper packaging and sanitary packaging. At present, polyurethane solventless glue is mainly used.
Problems currently encountered:
Solvent-free adhesives have low initial tack, and it is easy to produce white spots when aluminum foil is laminated, which affects the appearance of the product. For packaging products with special requirements (such as cooking packaging, liquid pesticide packaging), the quality of solvent-free composites cannot meet the requirements. Our solvent-free compounding problem is basically solved.
Experience in use: Solvent-free is most suitable for the structure of composite products with simple structure and single product type. At present, the main process bottleneck of solventless compounding in China is that the adhesive force of the adhesive needs to be improved, and the number of solventless equipment manufacturers should increase.
Personally, I think that with the country's requirements for environmental protection and safety, the process level of solvent-free compounding will become more and more, and the application range will become wider and wider, and it will become the mainstream compounding method.
19.Chen Changwei, Qingdao Hyde Packaging Co., Ltd.
Compound status quo:
The Spanish solvent-free composite equipment introduced by our company in 2009 was mainly for environmental protection and cost considerations. At present, we start it 24 hours a day, and the NY / PE structure is more complex. The glue brands used are Henkel and Bostik.
Problems currently encountered:
Now it is mainly a white point problem, which is not easy to solve!
Experience in use: Solvent-free is most suitable for composite BOPP / CPP structure products.
Solvent-free compounding is an inevitable trend for high-temperature cooking products in the future, and the share of traditional dry compounding will be less and less.
20. Zhang Zhifei, Zhongshan Tiancai Packaging Co., Ltd .:
Compound status quo:
Our company introduced a Nordmark equipment in 1997. At that time, the main packaging of Wrigley's gum was PET / paper structure. Now the machine utilization is high, three shifts, and basically full load operation. The glue is Rohm and Haas. At present, the main composite structures are: BOPP / CPP, PET / PE, NY / PE, PET / VMPET / PE or CPP (second pass), PET / AL / PE or CPP (second pass) and other structures. To date there are no mass-produced structures and products: PET / VMPET, PET / AL, and steamed and poached products.
Problems currently encountered:
PET12 / PE35-60μ (white), PET / VMPET / PE35 ~ 60μ, this kind of auxiliary unwinding is made of PE. When the thickness of PE film is uneven or edged, the composite film is easy to appear within 200M near the die Wrinkling, during which time the process is being perfected.
Personally, I believe that the solvent-free composite method has a bright future, and has significant advantages compared with dry compound: environmental protection, economical (small sizing amount, no solvent required), and high efficiency. At present, due to the limitations of glue, equipment and domestic personnel, solvent-free compounding has its own limitations. However, from the current domestic situation, many manufacturers prefer solvent-free laminating machines when adding new laminating machines, and some have even purchased two or three. I believe that in three to five years, the solvent-free laminating machine will be introduced by most soft pack manufacturers. Within five to ten years, the solvent-free laminating ratio will account for 40% ~ 60%, and sooner or later it will become the mainstream laminating method.
Second, the startup rate is not high, the perspective of the company in the run-in period
1.The boss of a color printing factory in Guangzhou
Status of use: A small part of the company's products are food packaging, and most of them are packaging for daily chemical products. In March 2013, I purchased the 1.3m wide solvent-free equipment of Tongze. When the equipment was first purchased, there was no problem. After using it for a period of time, there will always be some small problems, such as some parts problems, and the amount of glue. It will change, such as 1.5g, and then it will become higher, sometimes the glue will overflow. At present, Xingri and Kangda glue are used. Kangda glue is good and very stable. In the future, Henkel glue will be used.
1. OPP // VMPET // PE, the original three layers were made of solvent-free. Later, there was always aluminization transfer and white point problems. Now the first layer is changed to dry lamination, and the second layer is solvent-free.
2. Sometimes there is a mismatch between glue and ink. Originally, the color of printed matter was very bright, and it was compounded with no solvent. After curing, the color of the printed film was spotted. This problem occurred once, but now it basically does not reappear, but it is also Worrying about it, the most worrying thing is that a certain link is not well controlled and a batch loss occurs.
3. Pure aluminum products cannot be compounded, such as OPP // AL, but the composite strength is not.
4. The smoothness of PE and the matching problem of ink and glue.
Experience in use: Our solvent-free effect is not particularly ideal, and it is still running-in period. Some structures have some quality problems due to the complexity of process control. Therefore, some three-layer products are often dry-coated with the first layer and solvent-free with the second layer. The biggest advantage of cost savings is still not playing well.
Development trend: Although the use of solvent-free processes has limitations and some minor problems, there are still overall cost savings over dry lamination, so we are optimistic about future development.
2. Fang Zhenxing, Technical Manager of Zhejiang New Landscape Packaging Printing
Status of use: I bought Tongze equipment in August 2010. The main products: food packaging accounts for 80%, daily chemical packaging accounts for 20%, the product structure includes OPP // CPP, PET // PE, and also tried PET // paper However, because the paper is very absorbent, the glue becomes transparent, and the whiteness of the paper decreases after compounding, which affects the appearance. At present, our solvent-free equipment is not operating much.
1. In PET // PE, the shrinkage of PE increases, and live wrinkles are generated.
2. The glue and ink are not matched well, causing air bubbles and appearance problems.
Experience in use: The solvent-free process has stricter requirements on the operator and the environment, and the preparation is more detailed than the dry compound. It is not suitable for two-layer materials with good barrier properties, because during the curing of the glue, the gas cannot be discharged, and air bubbles are easily generated. The mixed rubber system must be cleaned frequently, otherwise it will be easily blocked and cause quality accidents.
The soft bag is an era of low profit. Now everyone is struggling with cost and staff quality. With the continuous improvement of solvent-free technology, its competitive advantage is still obvious.
3. Li Zhixiang, deputy general manager of Cangzhou Wonderful Plastic Printing Co., Ltd.
Status of use: In the second half of 2013, Tongze equipment was purchased. The equipment with a maximum mechanical speed of 600m / min was purchased. It is mainly based on considerations of saving money, safety and energy saving. Our company mainly makes food packaging. The product structure includes PA // CPP, PET // VMCPP, PA // PE, PET // PE, mechanical speed will generally open to 400m / min.
Use problems: The machine was purchased recently, and the machine has been debugged. Now it has begun production, so no problems have been found for the time being.
Experience in use: There is no actual experience in using it, but I feel that to use solvent-free, we must first understand what problems are prone to this process, and make corresponding preparations in advance and accumulate troubleshooting methods.
Development trend: Our company originally had 3 dry and double lines. Now that we have bought a solvent-free equipment, we will eliminate one of the dry and double equipment, and we are optimistic about the development of solvent-free.
4. A flexible packaging printing company in the north
Compound status quo:
Tong Ze SSL1000 purchased by our company was purchased in October 2013, based on the consideration of reducing compounding costs. At present, the start-up rate of solvent-free composites is not high, and it is in the process of summary. From light packaging such as OPP / CPP, OPP / VMCPP, OPP / PE, to freezing, boiling, and cooking are all ready to be done. The glue brands used for solvent-free compounding are being tested and selected. Different brands of glue have their own characteristics and need to be comprehensively balanced.
Problems currently encountered:
Some problems are being solved innovatively, which is also a common problem that the industry will encounter.
Solvent-free is most suitable for composite structures with at least one side of poor barrier properties. If both sides have good barrier properties, it is really difficult to solve the appearance.
The biggest bottleneck is the unpredictable quality of PE raw materials, which are produced by small factories. The management level and the stability of the process formula are difficult to guarantee. It is also the most difficult part to standardize in the process. If it is not accurately controlled, peel strength, The friction coefficient is unstable.
In addition, the captains of the entire industry have a low level of understanding of solvent-free composite technology. Some can only turn the machine up, and many common sense things are still unclear. What's more frightening is that this level, even the wrong cognition, will be passed on to the next generation of captains, forming an inherent experience, so it is difficult to improve it.
Qualified companies will be solvent-free, but there are still more companies with an annual output value of less than 30 million. At least they will not follow up at this time. It is only a trend whether they become mainstream, but it should be no surprise that the applications are becoming more and more widespread.
Third, the conclusion
In the communication with the enterprises, we found that the current high startup rate and the use of solvent-free composite technology are very good companies, but also paid the price of losses, but these companies have not flinched, but actively work with suppliers to find problems Root, continuously sum up experience, and improve the management process, finally successfully mastered the know-how of using solvent-free compounding. These companies have emphasized the importance of management without exception, because solvent-free compounding is a process that requires all parameters to be controlled before compounding begins; and after the end of production, equipment and accessories must be strictly maintained and cleaned. These things require meticulous implementation by employees, and they are a test of the quality of enterprise employees and the management of enterprise processes. In the beginning, it also experienced a period of groping and testing, but this period of time was short or long. At present, the startup rate is not high, companies that have just purchased a machine and are still in the exploration stage have also realized this problem. With the continuous maturation of solvent-free composite technology, equipment and glue are becoming more and more mature. As long as the company explores with heart and has the spirit of research, it is not difficult to use solvent-free composite. With the common growth of equipment, glue and flexible packaging companies, it is believed that solvent-free compounding will be more widely used in China.
This article is excerpted from the special issue of "solvent-free composite process".