Talking about the printing of textbooks with "five fears"

At present, China’s elementary and middle school students’ teaching materials have not yet been promoted for recycling. There are billions of copies of textbooks to be printed every year. “The words before the class and the number of manpower” summarizes the whole picture of the primary and middle school students’ textbooks. It also created the sweet, bittersweet taste of books, magazines and enterprises during the printing and production of the textbooks in spring and autumn.

In the short period of three months in which primary and middle school students stay in the cold and summer vacations, books and magazines throughout the country can be said to be the busiest printing season in the whole year. Overtime, dedication, and dedication to printing textbooks are the top priorities for production. The huge amount of textbooks has allowed each newspaper and magazine company to print sooner, hurry to finish bindings, submit books as soon as possible, and take more copies of some textbooks to print. Although the unit price of printed textbooks is lower, due to the huge number of printing, the economic benefits that can be generated in this short three months may account for 70% or even more of the whole year, so the annual benefits of books and magazines and enterprises are higher. Basically, look at the printing of textbooks in these two seasons.

How to further increase production efficiency, maximize the effectiveness of production equipment, and full load of printed materials are the key tasks of production management. However, some subjective and objective factors that affect efficiency and efficiency are also existed. The author summarizes: There are five fears printed.

"I'm afraid": Stamped sheets

Zero-sized printed sheets refer to single pages, one folded signature, and other discrete printed sheets in the binding sequence of books and periodicals. Primary and secondary school students’ textbooks are subject to overall cost constraints. 16 copies of the 3 sheets and 32 sheets of the 2 sheets of stamps are used for saddle-stitch binding. The materials larger than the aforementioned stamp sheets use wireless glue.

Due to the need to reduce costs, the paper for the medium is thinner, generally only 50 to 60g/m2 of light paper. The signature of the zero-page print is too light and soft, and it is difficult to smoothly and consecutively release on the high-speed glue-binding production line. , Frequent stoppages, such as placards, empty placards, multiple placards, shrinking placards, card machines, etc., often occur, thereby affecting the quality of placards and production efficiency.

Because of the large number of textbooks printed, in order to increase production efficiency, the internal text printing is basically a rotation method, and only the linkage production line can meet the requirements of the production schedule when printing and binding. The usual practice is to print the signatures of the stamps in advance, which are limited by the performance of the equipment. The printed stamps must be manually paged (also called pull-ups, splits), and the 0.25-page stamps with 16 copies are Example: Each off-print printed off-page booklet must be manually paged three times in a row in order to separate out the 0.25-page booklet in the quad. The signatures of the separated stamps still need to be pasted in sequence on other two-fold or more pages to form a thicker, stiffer signature in order to meet the production requirements of the linkage production line. This sticking process is Manual or sticking machine completed. The printer of the author's printing company has limited stickiness because of the limited stickiness of the sticking machine. Once there is a large-input-printing, zero-stamping signature copying task, almost all employees who can use it should be assigned to work overtime and sticky pages. It can be seen that it takes a lot of manpower, material resources, and time to deal with the zero-page stamp. As the upstream publishing department may not understand the book binding or create a stamp sheet to reduce costs, in the face of honorable customers, in order to be able to re-sign up to the printing sheet in the future, the downstream books and magazines and enterprises can only passively suffer silently. Dare to propose to the publishing house the improvement requirements that are conducive to improving production efficiency. Therefore, it is undoubtedly a painful thing for Indian enterprises to print copies of stamps.

"Two fears": Inserts

The paper for inserts will be different from the ones in the text. Most of them will be thick, usually coated paper of 105 to 157 g/m2. Because the interleaf paper is thicker and heavier, a single page can also be smoothly and consistently posted on the high-speed adhesive-bonded linkage production line. It is no longer necessary for stickiness, but it is also due to the difference in the use of paper. The cost is not over-consumption. In the general context, low-grade and low-priced hot-melt adhesives are commonly used. The current market price is around 13~15 yuan/kg; paper with 80g/m2 or more can guarantee the product quality and improve the adhesive strength. With high-priced mid-range hot-melt adhesives, the market price is about 16~18 yuan/kg; while 105g/m2 or more of coated paper must use higher-priced hot-melt adhesives, the market price is 25~40 yuan/kg. about. With ordinary hot melt adhesive to glue, insert the page is very easy to open plastic page, affecting product quality; with a little better hot melt adhesive to glue, the production cost is too high. Originally, the gross profit of processing textbooks was very low. It only depended on large volumes to maintain profitability, and the material consumption was increased passively, which greatly reduced the profitable space for enterprises.

Some printing companies have complete equipment after printing, using an interleaf and text to broaden the process of sticking the surface, using high-viscosity adhesive glue to increase the viscosity of the sticky mouth from the usual 3mm to 5~6mm. The use of better middle and high-grade side adhesives to ensure the quality of the package, and the practice proved to be effective, is an additional increase in the sticky process. For inserts with more than one fold in the folds, widen the pulp at each crease so that the inserts can also become glued signatures after milling, but the folding printers are not very printed Popular equipment, such as artificial sticking, is destined to be very low.

At the same time, due to the thicker interleaf paper, most of them are printed with a lithographic sheetfed printer. More than a fold of inserts, the printed printed sheets will need to be folded into a folder on the offline folding machine again, and the number of additional processes will have a certain impact on improving the production efficiency of printed books and periodicals.

With respect to insert construction in textbooks, books, magazines, and enterprises can only face difficult choices in terms of efficiency, profitability, and quality.

"Three Fears": Active Graphic Design

With the development of computer hardware and software technology, the layout design of textbooks has also changed from the predecessor format in the past. The layout design is very active and it is quite like the likes of elementary and middle school students. However, some designs that are too active, fancy, and dispensable are often counterproductive. Books published by enterprises and printed enterprises may be printed in the hands of the editors. The books may be printed beautifully, and they all meet the design requirements for editing. It is not expected that the sample books submitted by books, magazines, and enterprises are carefully selected by experts, even if they are specifically designed for specific equipment and materials. The only purpose of the cost and cost is to make a good impression on the publishers, and they are eager to accept more print orders in the coming year.

The materials printed in large quantities, especially those printed in the form of book presses and offset presses, are unlikely to have such satisfactory results: graphics and color blocks that shouldn't be bleeding are cut in batches; Bleeding; specific book brows, page numbers, title maps, etc. are too large. These problems are concentrated in some specific and special requirements in the layout design. The reason is that the layout design is too ideal, only to see the effect of the frequency screen or proofing, but does not seriously consider the objective of the entire printing production process. factor. The reasonable errors of various production and printing processes are accumulated till the end. Excessive deviations will be highlighted. Some high-quality books and magazines and enterprises will use technical documents such as modifying documents and excavating films according to the specific conditions of the production process of the unit. The corresponding process requirements are handled by themselves. These secretly reprocessed treatments are also destined to consume a lot of manpower and material resources, and books and magazines and enterprises that do not have a certain strength are unable to do so. Only in the batch printing strengthen the management, multi-monitoring, for some difficult to control in place of books and magazines are basically able to leave the factory are released, as long as it does not affect the reading, appearance can be passed on it.

Example: The specification of a finished book is 16 pages wide, 8 sheets printed, and the finished product size is 297×210 mm. In the layout design, each page of the head of the bookhead color bleeding, the bookbrow text is the number 4 black body against white, only 2mm away from the end of the finished product, the number of print has 500,000, the text is printed in positive and negative four-color. Due to the large size of the printing, 8-color book rotation was used to print in two batches. As it is a film that comes from the publishing house and a sample book, the quality inspection department can see that there is a sample printing, and the self-made film folding requirements are also in line with the technology of the unit. A simple check of the quality of the film will be released after being qualified. Can be sent to the printing shop to print. The quality of the ink printed by the printing department is similar to that of the sample. The folding order is also normal, and the printing is fixed. The first batch of 200,000 copies printed is printed and bound into a booklet. As a result, after binding books into books and books, it was discovered that about 5% of the book posts, that is, 10,000 copies of the book's eyebrows at the head of the head were accidentally cut in a small amount (less cutting of the size of the head of the head, and there was also a continuous phenomenon of the head of the sky). Although it does not affect the identification, almost every printed sheet has 3~4 places, but the word is definitely unqualified, and it communicates with the publishing house and rejects more than 800 books that have been seriously cut to the word formation and the characters are unrecognizable. After the goods, conceded factory.

After analysis, there is a 0.5-1.5mm deflection error in the printed sheet after the printing press has been printed on the book and periodical press; there are deviations of about 0.5mm in the bookbinding after printing, and the cutting position deviation will also occur when the finished product is cut. There is 0.5~1mm. These are very reasonable and normal deviations, which are not inconsistent with the quality requirements required in the work instructions, and also meet the quality requirements of national textbooks and textbooks. However, the slightest deviations are piled up together and the disadvantages of excessive deviations are revealed. It is objectively there, and it is not the adjustment, replacement of equipment, personnel can solve it. The problem lies in the fact that the quality inspection department fails to earnestly review the requirements: The sample text of the customer's sample is printed by octal digital printing. Only one fold is required, and the deviation is very small. It is assumed that there is no problem in other organizations; The film has failed to cross-hatching, and the headline text of the bleeding should not be too close to the finished product 2mm. There will be deviations when the rotary printing is folded in batches, and it will be easily cut. The reasonable deviations of various processes after the printing and binding cannot be taken into consideration. . Finally, according to the production process requirements of the unit decided to change the film, pull open the first page of each page 1mm, folding from 297mm to 298mm, post-press processing requirements are basically unchanged, requiring flexible adjustment of the cutting position and according to the specific situation At the end of the second batch of 300,000 copies, the size of Tiantoushumei was only twenty copies of Chinese characters, basically meeting the quality requirements and successfully completing the printing task.

"Fear": series of books printed

In the printing of textbooks, there are many series of books. In order to facilitate management, publishers often send the same variety of books to the same books, magazines, and enterprises for printing. For printers, it is of course a good thing to contract more orders to more orders, but it is not necessarily a good thing to take series books. Printing a series of books with almost the same content may also be a chore. After all, there is a great opportunity for mistakes. .

For example, a variety of textbooks are distributed in the province and abroad, and are commissioned to be printed in the factory. A total of 200,000 copies are printed. The copy, printed sheet, cover, text, printing order, printing color, and paper are all the same. The content of a line in the copyright page of the content is slightly different. It is represented by 01, 02, 03, and 04 respectively: the province's regular edition, the province's free edition, the province's ordinary edition, and the provincial free edition. It is not as specified in the previous seal or cover. This requirement has not been effectively implemented throughout the entire printing process. It is simply stated on the production subpena. It failed to cause quality inspection, printing, and the printing department pays high attention to printing. Only to find that all are confused, only to start the whole plant employees open the package page by page inspection, time-consuming work, and made it very passive. Of course, the responsibility lies in printing books and periodicals, strengthening management, and putting in place a guarantee mechanism for ensuring production. However, it is not easy to be able to stay awake during the busy printing season.

"Five Fears": Improper Cover Finishing Process

In the printing of textbooks, sometimes the improper finishing of the cover will cause a lot of trouble for the books in printing and use.

Taking 16 copies as an example, the publishing house requires 4 sheets of adhesive-bound cover with 120 to 128 g/m2 of coated paper, and 4 pages of cover with 157 to 200 g/m2 of coated paper. In order to improve the durability of the textbooks, the publisher asked for a comprehensive glazing of the cover for the so-called environmental protection. This change greatly increased the difficulty of production from the point of view of the printing factory. In particular, the number of wireless glue-covered paper sheets below 4 sheets was considered at the lower limit of 120 g/m2. The coated paper was lighter and thinner, and was easily curled after being irradiated with UV light. With electrostatic adhesion, this machine wastes more when it is on the cover. According to the author's statistics in the past few years, the cover of the glazing covers 100%~200% more than the cover of the same type with or without a film. This is the phenomenon whether it is saddle stitching or wireless binding. The additional increase in production costs cannot be ignored and should be given high priority. Another 120g/m2 of paper, especially domestic coated paper, due to manufacturing process, but the quality is not stable, poor degree of rigidity, soft, in the glazing processing production costs are quite large.

From a practical point of view, the cover of glazing can only play the role of protecting the imprint of the cover. It does not have the function of wear-resistance, tear-resistance, and stretch-resistance of the cover of the film, and protects the long-term durability of the textbook. A week or two after the book is put into the hands of students Most of the covers may be torn or torn due to carelessness of the students, and some of the cover of the coating may be unstable due to the coating oil components, leaving unpleasant odors. Parents will turn to printing books, magazines, and enterprises for complaints. Indian enterprises are very difficult, after all, books and magazines and enterprises are only processed according to a single order.

From a process point of view, the emerging film-covering technology has abandoned the traditionally harmful hot-pressing or film coating process, and has been changed to a normal-temperature, odor-free, non-hazardous water-based film coating process with environmental protection features. The cover after film coating is not easy. Due to the influence of the external environment, it is smooth, free from static electricity, and suitable for the production of this package. As a dual identity of the printing practitioners and the parents of the students, the author has far more advantages than comprehensive coating in the finishing of the textbook cover.

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