Recycling and recycling of cutting waste

In the printing production process, some people can only see the waste and trash generated after the paper is cut, while others see the value hidden behind the waste. If an industry is always overly concerned about the status of each money, then it may lose the opportunity to turn waste into treasure.

When printers think about making money all day long, thinking about buying large equipment from press makers such as Heidelberg, KBA, and Manroland, there are also manufacturers such as GF Puhl, Vecoplan, Ohio Blow Pipe, Air Systems and Design, as well as the United States, Bello, etc., although no other company is so famous, but they can give those who use Komori and Mitsubishi printing presses to bring higher returns on investment.

Recycling and marketing these scraps is very tempting for printing companies that often produce large amounts of production scrap. The Quad printing company in Sussex, United Kingdom, is particularly in line with the above-mentioned situation - if a printing plant can use waste paper to fill the entire waste container, then it can obtain at least 1.8 billion US dollars in revenue each year. According to Pat Rock, director of waste recycling at Quad Printing, Quad company produces an average of 1,500 tons of printing and finishing waste per month. This does not include the loss of signatures and wasted white paper. If, on the whole, the company produces about 4,500 tons of waste every month.

Major equipment

With the increase of business volume and the gradual aging of the paper recycling system, Quad Printing Company decided to establish a new large-scale waste recycling system. So this North American largest private commercial printing plant let GF Puhl help it design and install what is said to be the largest cutting waste collection system in the UK. The company installed seven 45-inch-high cyclones in its own 15,000-square-foot facility, and each cyclone can reach 50,000 cubic feet per minute, which is not enough. A hot air balloon is filled in two minutes. In addition, they also installed four new large-capacity automatic balers and conveyor belts, as well as a cutting waste collection system. The collection system also has a two-meter-long pipe.

In determining exactly how big a recycling system a plant needs, Quad measured the speed of the packer and the amount of waste generated. Rock said: "We always wanted to have a spare production line. This way, when we are maintaining our equipment, we don't need to shut down equipment such as binders, saddle stitchers, mailers, or paper cutters. They can Uninterrupted normal production, and we can continue to maintain the equipment."

The size of the recycling system depends on a complex formula, which is mainly related to the volume of air and the production of waste. Quad Printing chose a baler that was faster than they needed because they wanted the baler to run at a lower speed than the maximum speed.

Although these systems are assembled by veteran manufacturers, and their huge cyclone devices can also give people a strong deterrent, but the printer can still control the cutting waste recycling system through a web browser. Rock pointed out that the operator can adjust the function of the recycling system through the touch screen, and Quad company also equipped the system with a larger control system.

Let's take a brief look at the job of cutting waste recycling systems. When the scrap comes with the product from a print processing line, it is about 85 meters per hour (7500 feet per minute), and then the pipe conveying the waste will turn horizontally and keep the speed low (68 meters/inch). Hours) until they are sent to the top of the cyclone device. At this time, the waste paper will suddenly decelerate and fall freely at a speed of 3 m/h, eventually reaching the bottom of the cyclone device.

The cyclone device separates cutting waste from dust-laden air, compresses the paper into 1,500-pound pieces of paper, and discharges the filtered air inside the factory or outdoors. The compressed paper can be sent to a factory that produces toilet paper, or it can be re-made into a beautiful writing paper or cover sheet.

Rock pointed out that the printing plant will take about three months to train the new employees who use the system, especially to handle the paper balers. Many people think that balers are the most dangerous one in the printing industry. Kind of machine. Because it has multiple converter valves and blower devices, plugging is the most common operating problem, and this is the most critical issue. At the Quad printing plant, clogging problems are always discovered as early as possible because they have an advanced inspection and balancing system.

Worry-free operation

The ease of use of the system is the most attractive. Rock said: “The best feeling for an operator is to get everything under control and have all the necessary knowledge. The diagram of the waste recycling system can accurately tell you the progress of the work. If it appears The problem is that the system not only tells you where the problem is, but also tells you how to solve it and who you should turn to when you can't solve it yourself."

Rock is not willing to disclose information related to ROI or cost, but he made it clear that so far Quad has been very satisfied with the performance of this recycling system.

He said: "The most important thing we do is to install the best equipment on the market for our factory, so that our core business - printing and binding product catalogs and magazines - can be maintained."

Publishers Printing recently installed a new waste recycling system at its factory in Lebanon Junction, which began operations in June 2005 and closed in March this year. In the nine months of its normal operation, two-thirds of the roofs of the baling workshop were to be replaced, and they would be increased by 20 feet.

According to John Hardin, the warehouse manager of the company, the recycling system with two cyclones is about 5,000 square feet in space. It also has a dust collector. This recycling system replaces the company's original system that is similar to its function, but its size and ease of use are inferior to it. Whenever an employee shifts, the old system must be shut down and the dust collection bins replaced. The new system directly requires an airlock to achieve continuous production.

Publishers Printing, on average, can produce 2.2 million pounds of recycled paper every month. Hardin pointed out that GF Puhl, which designed the system, took full account of the company's current and future needs when determining the size of the cutting waste recycling system.

Another advantage of this system is that it can be connected to service technicians via telephone lines. As long as problems occur, technicians can easily find the source of the problems and resolve them as quickly as possible.

Prepare for the future

Hardin pointed out: "This system is very efficient and can give people a cleaner working environment. Of course, with the help of the RG42 PLX/60 Vecoplan shredder, we can easily handle printing and binding. Waste from the workshop. We know we need to completely update the waste collection system, and we are also doing so. By installing a new recycling system, Publishers Printing Company has prepared for future waste and dust collection needs."

Not all systems can achieve the desired recovery effect, and do not attempt to calculate specific figures for the return on investment. Bedford can produce about 100,000 pounds of cutting waste per month. Before installing the recycling system in the summer of 2005, the paper produced by the cutters and saddle stitchers was thrown into a giant Gaylord waste carton. When these boxes are filled up, the machines will stop running, and people will put these untreated waste boxes on trucks and ship them to recycling companies.

In fact, recycled paper can bring shocking benefits to printing companies. Franz Beisser, one of Bedford's chief executives, pointed out: "If you make good use of these scraps instead of throwing them away, you may be able to get more income - perhaps twice the previous income." In addition, if you do not have a truck with a particularly strong loading capacity, recycling waste can save you a lot of shipping costs."

He said: "The only problem we face when calculating the return on investment is that we cannot count the number of scrap pages. They are changing at any time. We do not know how many scrap pages will be generated in the next six months, even It is not expected to produce waste in the next month or two months."

This system installed by Air Systems and Design covers an area of ​​400 square feet. Due to its relatively small size, this system consists of a 40-hp engine fan, rather than a cyclonic device. Balers and air filters are placed around this system.

The main reason why Bison Printing Company introduced the new system was that the company's bindery and old-fashioned cyclone devices could no longer meet production requirements. The new system has brought amazing results to them, and the system does not require companies to pay for it for maintenance and maintenance. In addition to this, the chance of it blocking the fault is also minimal.

In addition to waste papers that can provide people with a higher return on investment, new recycling systems (especially those equipped with air filtration systems) can also save users a lot of heating and cooling costs. Older systems, which do not have a filter, require Bison to reheat or cool the air, resulting in a waste of energy costs.

Ultimately, scrap recycling can earn you more productivity and more money - no matter how small the waste - this is the most important point.

Beisser said: “We used to constantly empty and transfer large numbers of waste bins. This is a big deal, because if you fill a lot of bins with waste every day, they are always full, and operators are more likely to Make mistakes. Now we don't need to do this. This new waste recycling system allows us to maintain long-term normal work without any errors."



Source: Jiagong Machine Grid