Here is the overall solution for detecting the quality of cigarette packaging printing:
Pre-printing inspection: Paper inspection: Physical properties of cigarette packaging paper are inspected, including thickness, stiffness, flatness, moisture content, etc. Thickness and stiffness must meet the production requirements of cigarette packaging to ensure that the paper can maintain good shape and stability during printing and subsequent processing; flatness affects the quality and effect of printing, and uneven paper may cause printing patterns to be blurred or misaligned; too high or low moisture content will affect the performance of the paper, and it needs to be controlled within an appropriate range. Ink inspection: Ink color, viscosity, and drying speed are inspected. The color of the ink should match the color requirements specified in the design draft and have good stability, not easily fading or changing color; viscosity affects the transfer and printing effect of the ink, and high or low viscosity may lead to printing quality problems; the drying speed should be appropriate, too fast or too slow will affect production efficiency and printing quality. Graphic content verification: Carefully verify that the text, graphics, barcodes, anti-counterfeiting markings, etc. on the cigarette packaging design draft are accurate and error-free. For example, the brand name, warning statements, tar content, etc. of the cigarette brand must be consistent with relevant regulations and standards; the design elements and layout of the graphics must conform to the brand's design style and positioning, and avoid situations where the graphics are incomplete, distorted, or inconsistent with the design draft. Color mode and resolution confirmation: Check whether the color mode of the design draft is CMYK four-color mode (the commonly used color mode for cigarette label printing), and ensure that the image resolution is high enough to ensure clarity after printing. Generally, the image resolution for cigarette label printing should be at least 300dpi or higher, and the resolution may need to be higher for fine patterns or text with special requirements. Design Review: Material Testing:
Inspection in Printing Process:
Online inspection system: Install online quality inspection equipment, such as high-speed cameras, image sensors, etc., to monitor cigarette labels in the printing process in real-time. These devices can detect defects such as missing print, incorrect print, smearing, misregistration, color difference, ink spots, and dirt, and issue alerts in time for operators to adjust printing machine parameters or stop the machine for processing. For example, when the misregistration exceeds the allowable range, the system will automatically issue an alarm to remind operators to adjust. Color Management: The use of a color management system for real-time color monitoring and adjustment during the printing process. By precisely controlling parameters such as ink volume, water-ink balance, and printing pressure on the printing machine, it ensures that the color of the cigarette labels printed is consistent with the design draft. Regular use of color measurement instruments to measure the color of printed products and adjusting the ink volume and color profile of the printing machine based on the measurement results to ensure the accuracy and stability of the color. Registration accuracy inspection: Utilize registration marks or detection systems to inspect the multi-color registration accuracy of cigarette labels. Ensure that the different color patterns, words, and other elements can be accurately registered together, avoiding issues such as ghosting and misregistration. During printing, regularly check the deviation of the registration mark position and adjust the registration device of the printing machine in time to ensure that the registration accuracy is within the allowable range.
Post-print inspection: Adhesion Test: The adhesion of ink, coatings, and foil decorative elements on cigarette packaging is tested using methods such as tape adhesion or friction testing. This ensures that these decorative elements will not easily come off during normal use and storage. For example, 3M tape is attached to the surface of a printed cigarette packaging, and then quickly peeled off at a certain angle and speed, to observe the loss of ink or coatings. Abrasion resistance test: The abrasion resistance of cigarette packaging is tested using a friction tester or manual friction method. The surface of the cigarette packaging is subjected to friction testing to check whether the text and graphics are easily worn, faded, or if surface scratches appear. For example, the cigarette packaging surface is subjected to a certain number of friction cycles using a friction tester, and then the degree of wear is observed. Barcode and QR code detection: Use professional barcode and QR code reading equipment to scan and read the barcodes and QR codes on cigarette packaging. Check the printing quality of the barcodes and QR codes to see if they meet the standard, whether the information is accurate and error-free, and whether they can be read quickly and accurately. Odor detection: Since the cigarette label will come into direct contact with the cigarette, it is necessary to check whether the label has any unusual or irritating odors. You can use your nose to sniff the front and back of the label closely to ensure that there are no obvious odors. Visual inspection: Under standard lighting conditions, the inspection is conducted at a specified viewing distance and angle to visually inspect the appearance of cigarette packaging. Check for surface defects such as scratches, scrapes, bubbles, folds, dirt, etc. on the cigarette packaging; check if the text and graphics are clear, complete, and free of missing characters, broken strokes, blurring, etc.; check if the colors are even, vibrant, and free of color differences. For example, inspect the surface quality and graphic clarity of the cigarette packaging at a viewing distance of 50cm while looking at it straight on. Dimensional Measurement: Use precision measuring tools such as calipers and micrometers to measure the dimensions of cigarette packaging. Check the dimensions of the cigarette packaging, including length, width, height, and diameter, to ensure they meet the design requirements and customer orders. Check whether the dimensional tolerances are within the allowable range. For example, measure the dimensional tolerances of the rectangular cigarette packaging to ensure that the length and width are within ±0.5mm. Appearance detection: Performance Testing:
Data Analysis and Quality Traceability: Data recording and analysis: Record and analyze quality inspection data during the printing process, including defect types, defect numbers, inspection times, and printing batches. Through data analysis, identify the patterns and causes of quality problems so that appropriate improvement measures can be taken. For example, by analyzing inspection data over a certain period of time, it was found that a specific printing machine was prone to register offset problems at certain times, which allowed for maintenance and adjustments to be made to the equipment. Quality traceability system: Establish a quality traceability system to trace the production process of each cigarette label. Record the raw material information, printing process parameters, and quality inspection data of the cigarette label to enable quick tracing of the source of quality problems and the implementation of effective recall and handling measures when necessary.
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