According to the research of Instititut für Druckmaschinen und Druckverfahren (IDD) of the University of Damstadt in Germany, the laboratory results show that a manual cutting line requires two people to complete the entire cutting process, and about 80% of the time is spent on transporting the paper from the pallet to the lifter. Then, because of manual handling in batches, the paper is in a jagged state, so an additional paper-jogging process is required. This process requires a certain amount of time to sort the paper. Moreover, the paper jogging time is affected by different factors such as paper status, paper weight, and paper type. Moreover, the physical fitness of the operators is quite tested. According to the 8-hour work day, 80% of the time is used for handling work, and 6 hours of the day are heavy manual labor. If the paper format is large, the labor intensity will be even higher.
Calculated according to the speed of an offset press at a speed of 12,000 sheets per hour (note that the offset presses of domestic printing plants basically work 7X24), the working speed of a manual cutting line is about 10000-15000 sheets/hour. In other words, two relatively skilled operators are required to work non-stop to keep up with the printing speed of the offset press. Therefore, domestic printing plants generally adopt multi-employee, high-intensity, and long-term operation of paper cutters to meet the needs of printing work. This will generate a lot of labor costs and potential labor damage to the operator.
Knowing this problem, Guowang design team began to organize technical forces in 2013 and set the goal on how to overcome 80% of the handling time. Because the speed of the paper cutter is almost fixed, even the most advanced paper cutter on the market is 45 times per minute. But how to omit 80% of the handling time has a lot to do. The company sets this future cutting line into three parts:
1st : how to take out the paper neatly from the paper pile
2nd: Send the removed paper to the paper cutter
3rd: Put the cutted paper neatly on the pallet.
The advantage of this production line is that 80% of the transportation time of the paper cutter is almost gone, instead, the operator concentrates on cutting. The paper cutting process is easy and efficient, the speed has increased by an astonishing 4-6 times, and the production capacity has reached 60,000 sheets per hour. According to the offset press at a speed of 12,000 sheets per hour, one line per person can satisfy the work of 4 offset presses.
Compared with the previous two people’s production capacity of 10,000 sheets per hour, this production line has completed a leap in production and automation!
Cutting line process detail:
The entire automatic rear-feeding cutting line is divided into three parts: automatic intelligent paper picker, high-speed programmable paper cutter, and automatic paper unloading machine. All operations can be completed by one person on the touch screen of the paper cutter.
First of all, with the paper cutter as the center, according to the layout of the workshop, the paper loader and the paper unloader can be distributed left and right at the same time or separately. The operator only needs to push the paper cutting stack to the side of the paper loader with a hydraulic trolley, and then return to the paper cutting machine, press the paper load button, and the paper picker will start working. First, use a pneumatic pressure head to press the paper from the top of the paper stack to avoid the paper stack from tilting during the paper picking process. Then a platform equipped with a rotating rubber roller on one side keeps the horizontal belt at a slightly inclined angle and decelerates before moving to a corner of the paper pile, and then descends to the paper height set by the computer. The photoelectric eye can precisely control the height. Then slowly move forward until it touches the stack of paper. The rotating rubber roller can separate the paper stack upwards without damage, and then insert the entire platform of the platform into the paper stack about 1/4 at the natural winding speed, and then the pneumatic clamp will clamp the paper stack that needs to be taken out. Release the pressure head that pressed the entire stack of paper in front. The platform rolls into the entire paper pile again at natural speed. Then the platform slowly moves to the back of the paper cutter until it completely leans against the side of the worktable behind the paper cutter. At this time, the paper cutter closes to the paper picker and the rear baffle automatically falls, and the paper picker pushes the stack of paper on the platform. Enter the back of the paper cutter, the baffle rises, and then the paper cutter pusher pushes the paper to the front according to the set program, which is convenient for the operator to take over. Then the paper cutter starts to work. The worker conveniently rotates the paper three times on the air-cushion worktable, cuts all four sides of the paper pile neatly, and pushes it to the prepared paper unloader platform. The paper unloader will automatically move the paper pile. Unload on the pallet. One-time cutting process is completed. When the paper cutter is working, the paper picker works at the same time. After taking out the paper to be cut, wait for the paper to be cut and then push it into the paper cutter again. Reciprocating work.
If you think the explanation is too long, check this video:
>Periphery equipment for paper cutting line
Post time: Sep-02-2021