Talking about the root cause of the quality problem of wireless glue binding
In recent years, with the acceleration of publishing rhythm, the number of books using paperback wireless glue binding has been increasing. According to incomplete statistics, China has printed approximately 12 billion books per year in the past two years, of which more than 50 Billions of books are processed into books by wireless binding. The thermal bonding material EVA hot melt adhesive used for bonding books and periodicals uses nearly 10,000 tons per year; there are more than 700,000 units that use such adhesive materials for book binding; wireless bonding equipment has only been linked to the production line. Hundreds, there are more than 3000 single machines. There are so many booklets processed by the glue binding process, and the large amount of bonding materials used, involving a wide range of processing units, is unprecedented in the history of book binding. However, it cannot be seen from the book quality inspection in recent years that the quality problem of book binding is also more serious. According to the relevant part, the unqualified products of binding account for about 65% of the total print quality problems, of which wireless adhesive The unqualified products caused by the order processing accounted for more than 80%. The unqualified products mainly reflected from the surface that the pages of the books and periodicals appeared after processing, the back of the book was uneven, the book block was broken, the air bubbles, the holes, the glue overflow, etc. Where does the reason come from? Now we analyze from the following points, so that the relevant units can find out the reason in the actual management work, be resolved, and improve the quality of wireless binding processing. 1. Inadequate understanding of the importance of changes in the post-press binding process The post-press binding process is the final decoration process of the entire process of the printed product and the final completion process of the book processing. It is related to the use value, preservation value and reading value of the printed product, and affects the above two processes (pre-press and printing) The processing effect and cycle guarantee; no matter how good the printed product is, if it is not correctly and firmly connected, the beautiful outer packaging will not reflect the value of the printed product. Post-press binding is a very important process in the final packaging of printed products. For a long time, people have always been prejudiced against this process, thinking that everyone can do it, and neglected its importance. At the same time, it has also caused the cultural quality of the people who have been engaged in this work for many years to be lower than the pre-press and printing processes. As one of the largest printing professional institutions in Asia, such as Beijing Printing Institute, there has not been such a special subject that accounts for one-third of the total printing industry in several years. It is only in recent years that there are some post-press binding courses (in the Department of Packaging and Decoration) . In large-scale printing information conferences and printing scientific research conferences, the pre-press and printing methods are generally discussed. For example, only the pre-press and printed matter processing can complete the mission, and the books can be read without being assembled into a volume. This situation will continue. Will the quality of book binding increase? The high quality of book decoration will affect the overall image of book publishing in China. Therefore, we must really draw attention to it. Post-press binding is a processing procedure with complicated equipment, complex technology, many kinds of materials, and large changes; as far as the equipment is concerned, there are dozens of types, more than 100 models and forms, and there are nearly 10 types of linkage production lines, and Each line has different models and forms, and the stand-alone equipment between the types of work has little in common. Post-press binding has gradually evolved from a manual operation process to a modern processing process of mechanized, linked, and automated equipment. The post-press binding process is more complicated and changes greatly. There are more than 10 kinds of binding methods alone, and some of the binding methods have more than 30 process flows. And the process changes a lot during processing. The publisher needs to process as much as required. As for Whether binding can meet the requirements is rarely paid attention to. There are hundreds of types and styles of binding materials, and each kind of material involves a lot of knowledge. For example, there are more than 10 kinds of cover materials with different textures. These different materials involve the use of bonding materials. Different is related to the object of bonding and the firm effect of bonding. The correct use of materials directly affects the firmness and shelf life of books. At present, the quality problems that occur in wireless adhesive bonding are directly related to the use of EVA hot melt adhesives. In short, the post-press binding process is not only a complicated processing process, but also an art processing process. Today's books are not only reading materials, but also a gift, artwork, and valuable preservation; it not only adds knowledge to humans, It also brings people artistic enjoyment. Therefore, the effect and value of printed products must be shown by the quality of the binding after printing. For our staff engaged in all aspects of book publishing and production, we must clearly re-recognize the complexity and importance of this process and the overall concept of making a book, and re-recognize and understand this process for publishing high-quality books. . Second, the equipment has changed, the personnel quality has not changed Modern post-press binding equipment has entered a period of mechanized, automated, and linked production. Especially after the early and mid-1990s, China has entered the third period of change in binding equipment, which is characterized by everything moving closer to international standards. At present, there are about 100 large-scale linkage production lines in China, and the price of the most advanced linkage line is nearly 20 million yuan: computer control, image display, etc., the equipment is getting higher and higher, and the management and operation of these equipment require a certain level of technology Management and operation personnel are competent. However, it is understood that there are currently very few talents in this area in our country, and the existing skilled workers are far from meeting the expected requirements; generally, the equipment is coming. Besides, some units only train personnel for a few days and let the machine operate. Most of the equipment is touched and the machine can be turned on. Therefore, the life of the equipment is shortened, the efficiency cannot be improved, and the quality of the finished product does not meet the standard requirements. The reason for finding people; as far as the quality of the post-press binding process is concerned, most of them are not graduated from professional schools or even have any training. How can they adapt to today's modern production with such a foundation? The equipment has become advanced, and the quality of people has not changed. How can we keep up with the trend of the times? 3. The process and materials have changed, and the environmental conditions have not changed As far as the wireless glue binding process is concerned, almost every book processing plant has to be involved. Most of the bonding materials used in this process are thermoplastic EVA hot melt adhesives, and the requirements for the environment and conditions of this thermoplastic bonding material are very strict when used. At the "Sino-German Bookbinding Technology Training Course" organized by Nanjing Aide Printing Co., Ltd., German teacher Mr. Stahl presented the importance of environment and conditions when explaining the use of EVA hot melt adhesive, and introduced the EVA hot melt adhesive in France. There are certain data controls for the temperature and humidity in the workshop where the booklet is processed. Among them, the temperature is controlled between 19 ℃ ~ 25 ℃, the humidity is controlled at about 50% RH; while China generally requires the temperature in the wireless perfect binding production workshop to reach 17 ℃ ～ 30 ℃; this requirement is twice as bad as abroad. But for such requirements, except for a few of the units and regions that can be achieved, most of them cannot be implemented according to this requirement. For example, the temperature in the south of China is high, many units have no constant temperature or air conditioning in the binding workshop, and EVA hot melt adhesive is used when the temperature is the highest The temperature of the workshop is as high as about 38 ℃, resulting in prolonged curing time after the glue is applied, no hardening and shaping, and the linkage production line cannot be cut. When the winter temperature is low in the north, the indoor temperature is the lowest (no constant temperature, air conditioning equipment) to about 10 ℃, which causes the hot melt adhesive to be cured in advance and cannot be bonded ... As for the temperature, due to regional differences, the standardization of enterprises is not perfect ( Generally, there is no hygrometer device in the bookbinding workshop), and it is very slim to meet the expected humidity standard; for example, in the south of China, where the rain is heavy, the humidity is high and the humidity is high. The humidity in the workshop is up to about 80% RH. The lowest can reach about 30% RH. If the humidity is too low or too high, it will have a direct impact on the binding and shaping effect of paper and books, and will cause various quality problems of wireless adhesive book binding. In order to improve the quality of book binding, in the binding workshop, especially where hot melt adhesive materials such as EVA are used, a good environment and conditions must be created to implement standardized production. [next] 4. Inadequate understanding of modern bonding materials There are two kinds of binding materials used for binding, one is cold hydrosol; the other is thermoplastic adhesive, which needs to be used after being qualified by hot melt. The bonding form of adhesive materials is divided into osmotic type, suction type and semi-permeable type (also called semi-attractive type). The bonding materials used in these three forms are different from the types of objects to be bonded, and the bonding effect is also Different. China's binding adhesive materials have used cold glue for a long time, cold glue is a water solvent, and its drying method is to set the shape with the temperature and time after heating and pressing. The thermoplastic adhesives commonly used in modern times are different. For example, EVA hot melt adhesive is a solid, moisture-free fusible adhesive material. The use of this material should pass the appropriate melting point (softening) temperature, use temperature, Opening time, curing time and cooling hardening time, and then correct clamping and shaping, can achieve reliable bonding effect. Because EVA hot melt adhesives are affected a lot when they are used, such as the temperature and humidity of the plant, the speed of the operation, the different paper textures, the different backing and side glues, the temperature of the glue, etc., are all related to the processed products. Pros and cons have a direct relationship. In addition, many publishers require that the thickness of the backing glue of the processing plant should be as large as possible. It is believed that the more the backing glue is applied, the stronger it is. This is a misconception. In fact, the fastness of the book connection is in a certain sense. Firmness does not matter. Because the strength, viscosity, viscosity, etc. of the adhesive can determine the book fastness. As long as the strength, viscosity, viscosity, etc. of the book back adhesive meet the standard requirements, the adhesive layer should be "thin and even"; if the book back adhesive is applied too thick, it can only cause the back of the book to be uneven, difficult to read, ugly, and waste rubber. There are many types of cold and hot adhesives for binding materials. Among them, EVA hot-melt adhesives have different bonding types due to different sources of basic materials, types of auxiliary materials, and differences in prices of various accessories. effect. Therefore, we must fully understand the various new materials used in modern times (including cover materials, cardboard, etc.), strengthen learning, clarify the theory and apply it to practice, record the use experience at any time and summarize it, and the ascending theory cycles in turn Improve to meet the ideal requirements. 5. There is little communication between the designers of the publishing house and the bookbinding processing plant In the past few decades, the publishing industry ’s design (especially the American editors) personnel often contacted the technicians and teachers of the bookbinding processing plant to absorb the opinions of the bookbinding workers to improve and enhance the design plan to achieve the design expectations and The consistency of product completion (that is, the imagination is consistent with the destination) has made many high-quality products that have won various international and domestic awards. There are many well-known artists of American editing. They take the initiative to make friends with the binding factory and masters, learn the binding process from them, and learn about various binding techniques to better design more excellent works. But in recent years, there has been too little such communication. At present, some younger American editors generally only pay attention to the news on the computer, and do n’t go to the factory to understand and learn the knowledge that is not available on the computer from the masters, and forget the practice. Be truthful. There are also artists who think they are designing and are future artists. They go to the factory to learn from the workers, but they ca n’t put down the shelves. Therefore, there are many problems in the design, the size of the selected materials, etc., the following are a few phenomena. 1. Regardless of the value and effect of books, blindly pursuing wireless glue binding processing The use (reading) value and preservation value of books are directly related to the correct selection of binding process methods and types of binding materials. In general, if you have high-end books with preserved value, you should choose long-term exquisite decoration processing; the binding materials must also match the grade of the book to obtain the desired effect; general books can be processed by universal installation methods; simple and short-use books and periodicals, You can choose the simplest method. However, we can see from the book market and the situation of book publishing nationwide that the number of cases of wireless glue binding. It currently accounts for more than 60% of the total number of books installed. The author does not deny that wireless adhesive binding has many advantages, such as fast book publishing, short cycle, suitable for modern rhythm, and low labor and material cost. However, this processing method also has many shortcomings, such as: ①resin adhesives are easy to age It is not easy to keep for a long time; ②Thick books are not easy to read and change; ③The binding is not strong, the pages are easy to fall, and they are broken, which has become the most binding method for book binding quality problems. However, in order to rush to publish books and want to reduce costs, some publishers reduced the useable thick books that should be bound in volumes or processed in hardcover to make a thick paperback wireless sticky book, resulting in problems. Unclear. There is a publishing house in Hebei province to make a book with a size of 32 (A5) and a thickness of 48mm, indirectly asking the author if it is possible to process wireless bound paperback? The author replied at the time: "No! Either do hardcover, or do 2 to 3 volumes of wireless bound paperback ..." As you can imagine, for example, such a small book really made a wireless bound paperback, and the result was : A. Unable to read (can't read without holding down); B. The front incision is uneven, and it stands out from the belly to become a rounded claw; c. The appearance of the whole book is changed; D. The page is broken, and the core of the book is broken; E. The bond cannot be firm, shorten the life of the book, and cannot be stored for a long time. China is the earliest binding technology in the world, and it is also the country with the most binding methods, styles and the oldest. There are more than 10 binding methods. There are also 4 or 5 commonly used binding methods. The choice is wide, but the current situation It is indeed not normal to use wireless perfect binding paperback for reading any book. Of course, it should be used, but do n’t use it if it should n’t be used, and it will eventually cause trouble and prevent good and valuable books from being properly saved and used. 2. There are countless problems caused by cover material selection and design There are many books that do not consider the processing difficulties and effects in the selection of cover materials, causing various quality problems. The following is one or two examples for your analysis. ①The thickness of the cover paper and the book block are quite different. In order to improve the book binding effect, there are many books with a cover thickness that differs greatly from the thickness (or weight) of the book block paper, resulting in unequal tension between the two. When the cover is lifted after wireless binding, the first page of the book block is pulled to expose the glue The bottom or sample pages cause unqualified products, and there is a conflict between the publisher and the processor. This kind of product can solve the problem of bottom leakage if a moderate weight (thickness) ring liner or title liner is added between the cover and the first page of the book block, but many publishers do not intend to do so at all to reduce costs. The processing effect is not considered. ②The crease of the cover paper material is not properly broken. Now the thickness of the cover is getting larger and larger. The cardboard or paper above 200 grams is designed with a folding front opening process. When the creasing is indented, the crease breaks and leaks, which destroys the appearance quality of the book. In fact, the front cover of 200g or more needs to be folded, so the book binding process is very difficult, and the quality cannot be guaranteed, so it causes quality problems. ③The length of the cover is shorter than the length of the book block, resulting in dirty books. During book binding processing, most of the cover length is about 7mm shorter than the book block. As a result, the end of the book is empty when the wireless binding is glued, which causes the exposed part of the book back to leak dirty books. If the burrs of the sky and the feet are left in the cover design, this phenomenon can be avoided completely. ④The design pattern leaves no room for processing. Other beauty editors have designed the cover with patterns and frames to take into account the difficulties in the binding process, and do not understand the requirements of the quality standards of the binding. They deliberately pursue the beauty of the appearance, and the desired effect is not achieved when the binding. For example, if a processing unit receives a paperback book from a publishing house with a thickness of 12mm, the cover design of the book is divided into black on all backs, and the first and fourth full editions are printed in black and white, requiring the processing plant to process The cover should not be exposed, and the back of the book should not be black. This requirement is too difficult. According to the national CY / T28-1999 binding quality requirements and inspection methods paperback "3, 4, 5" provisions: the back of the book translation error is based on the center line of the back of the book, the thickness of the back of the finished book is less than 10mm, the back of the book translation tolerance It is ≤1.0mm; for the finished book with a thickness of more than 20mm and less than or equal to 30mm, the tolerance for the translation of the back of the book is 2.5mm; for the finished book with a thickness of more than 30mm, the tolerance for the translation of the back of the book is 3.0mm. The tolerance of the skew of the back of the book is 0.5mm smaller than the tolerance of the translation of the back of the book, so how can this kind of black and white distinct design meet the demanding requirements of the processor, how can it achieve the desired effect? There are too many examples. It is hoped that publishers should communicate more frequently with the binding and processing units, correctly understand the overall concept of a book, and work together to make a book well. Landscape Artificial Grass,Fake Green Grass,Grass Floor,Flat Roof Artificial Grass Changshu Keyuan Eco-friendly New Materials Co.,Ltd , https://www.alqartificialgrass.com