At present, China ’s primary and secondary school textbooks have not yet been promoted and recycled. Billions of textbooks have to be printed every year. The eight words “Before class, book one hand†summarize the whole picture of primary and secondary school students ’textbook printing. It has also created the sweet, sour, bitter and bitter taste of book printing companies in the spring and autumn textbook printing and production process. In the short three months of primary and secondary school students' winter and summer vacations, the nation's book and printing companies are arguably the busiest printing season of the year. Working overtime and working hard to print textbooks is the most important thing in production. The huge volume of textbooks makes every book and printing company want to finish printing early, finish binding quickly, hand in the books as early as possible, and take more shares in the printing of textbooks. Although the unit price of textbook printing is low, due to the huge number of printing, the economic benefits of income generated in these three months may account for 70% of the whole year, or even higher, so the book and printing enterprises benefit from the whole year Basically, it depends on the printing of the teaching materials in these two seasons. How to further increase production efficiency, maximize the effectiveness of production equipment, and rush to print textbooks at full load is the focus of production management. However, some subjective and objective factors that affect efficiency and efficiency also exist. The author summarizes the following: teaching materials Printed with "five fears". "Afraid": fractional print Fragmented printed sheets refer to single-page, one-fold book signatures and other loose-printed sheets in the book binding sequence. Textbooks for elementary and middle school students are subject to the overall cost constraints. The 16-sheet format with 3 printed sheets and the 32-sheet format with 2 printed sheets or less are saddle-stitched. Textbooks larger than the aforementioned printed sheets are wirelessly bound. Due to lower costs, the internal paper is thin, generally only 50 ~ 60g / m2 light paper, and the signatures of the fractional prints are too thin and soft, it is difficult to smoothly and consistently post on the high-speed glue binding production line , There are often failures such as crooked posts, empty posts, multiple posts, reduced posts, card machines, etc., and frequent parking, which affects the quality of post matching and production efficiency. Because the number of printed materials is very large, in order to improve production efficiency, the internal text printing is basically a rotary method, and only the linkage production line can meet the requirements of the production schedule when binding after printing. The usual practice is to print out the headprints in advance. Due to the limitations of the equipment performance, the printed headprints must be paginated manually (also called brushing and splitting). The 0.25-printed signatures in 16 format are used as Example: For each printed signature printed by open rotation, it must be manually paged three times in succession to separate 0.25 printed signatures in four-pack. The separated signatures still need to be adhered to other signatures with two or more folds in order to form thicker and more rigid signatures to meet the production requirements of the linkage production line. Finished by manual or page sticking machine. The printing company where the author has worked has limited sticking ability of the pager. Once a large number of prints are printed, almost all employees who can use it must arrange for overtime paging and sticking. It can be seen that a large amount of manpower, material resources and time are required in order to deal with piecemeal printed signatures. As the upstream publishing department may not understand the binding of books or periodicals, or in order to reduce costs, it has caused fractional prints. In the face of esteemed customers, in order to be able to contract for printing in the future, as downstream books and periodicals printing companies can only passively bear, not Dare to propose to the publishing house the improvement requirements that are conducive to improving production efficiency, so it is undoubtedly a painful thing for printing companies to process the signatures of odd-printed sheets. [next] "Two fears": Insert The paper used for inserts will be different from the text. Most of them are thick and heavy, usually 105 ~ 157g / m2 coated paper. Because the interleaf paper is thick and heavy, a single page can be smoothly and continuously posted on the high-speed glue binding production line, and there is no need to stick, but also because of the different paper, the glue cost of wireless glue is increased: to ensure production The cost is not excessive, the general text generally uses low-grade and low-cost hot-melt adhesives, the current market price is about 13 ~ 15 yuan / kg; paper with 80g / m2 or more, in order to ensure product quality and improve tack strength, will Use high-end mid-range hot melt adhesives, the market price is about 16 ~ 18 yuan / kg; and the coated paper above 105g / m2 must use higher-grade hot melt adhesives with higher prices, and the market price is 25 ~ 40 yuan / kg. about. Use ordinary hot-melt glue to glue, it is easy to open the glue at the inserting page and affect the product quality; use a better hot-melt glue to glue, the production cost is too high. Originally, the gross profit of processing textbooks is very low, only relying on a large amount to maintain profitability, and the material consumption is passively increased too much, which greatly reduces the company's profitable space. Some printing companies are fully equipped after printing, using the process of inserting pages and text to widen the sticky surface, and using high-viscosity glue to increase the sticky width of the mouth from the usual 3mm to 5 ~ 6mm. Using a better middle-to-high-end side glue to ensure the quality of the package, the practice has proved to be effective, that is, the additional adhesion process. For inserts that require more than one fold, at the time of folding, a wide paste is placed at each crease, so that the insert can be glued to the signature after milling, but the printing machine with the extra paste function is not very good. Popular equipment includes, for example, the use of artificial sticky methods, the production efficiency is destined to be very low. At the same time, because of the thicker interleaf paper, most of them are printed with lithographic sheet-fed printing machines. For inserts of more than one fold, the printed sheets need to be taken off-line and folded on the folding machine to form a post. There are many additional processes, which have a certain impact on improving the production efficiency of book printing. For the construction of inserts in textbooks, between efficiency, profitability and quality, books, periodicals and printing companies can only face difficult choices. [next] "Three fears": active graphic layout design With the development of computer hardware and software technology, the layout design of teaching materials has been changed from the previously invariable layout. The layout design is very active, and it is very popular among elementary and middle school students. But some designs that are too active, fancy, and optional are often counterproductive. The sample books sent by book and printing companies to the editors of publishing houses may be printed very beautifully, and they can meet the design requirements expected by the editors. However, the sample books submitted by book and printing companies are carefully selected by specialists, even with specific equipment and materials. The cost and price are specially printed, and the only purpose is to make a good impression on the publishing house, eager to get more printing orders in the coming year. Textbooks printed in large batches, especially those printed by book offset printing presses, may not have such a satisfactory effect: the graphics and color blocks that should not be bleed are cut in batches; Bleeding; specific headers, page numbers, title maps, etc. are too large, etc. These problems are concentrated in some places with specific and special requirements in the layout design. The reason is that the layout design is too ideal. I only see the effect of the frequency screen or proofing, and I did not seriously consider some objective in the entire printing and production process. factor. The reasonable errors of various production and printing processes will accumulate to the end, and excessive deviations will be highlighted. Some highly skilled books and periodicals printing companies, according to the specific conditions of the production process of the unit, adopt technical means such as file modification and film modification. Handle by yourself according to the corresponding technological requirements. These secretly reprocessed processes are also destined to consume a lot of manpower and material resources, and books and periodicals printing enterprises without certain strength cannot do so. It can only strengthen management in batch printing, monitor more, and basically release some books and periodicals that are difficult to control in place, as long as it does not affect reading and the appearance is passable. Example: The finished product specification of a book is 16 open, 8 printed sheets, the finished product size is 297 × 210mm, and wireless binding is used. In the layout design, each page of the head of the head has a bleeding color block. The text on the head of the head is black on the 4th. The distance from the head of the head is only 2mm. The number of printed pages is 500,000. The text is printed in four colors. Due to the larger printing, eight-color books and periodicals are used to print in two batches. Since it is a film provided by the publishing house and a sample book is attached, the quality inspection department can see that the sample is printed. The folding requirements of the film are also in line with the process of the unit. After a simple check of the quality of the film, it will be released after it is qualified. Can be sent to the printing workshop for printing. The quality of the ink color printed by the printing department is not much different from the sample, and the folding order is also normal. Then the samples are set and printed. After the first batch of 200,000 copies are sent for printing, they are bound into a book. As a result, about 5% of the signatures, that is, 10,000 copies of the header text at the head of the book, were accidentally cut into a small amount after the book was bound and bound, and the book was wrapped into a book. Although it does not affect the recognition, almost every print has 3 to 4 places, but the word is definitely unqualified when it is cut. Communicate with the publishing house and reject more than 800 volumes that have been severely cut to form characters that are blind and unrecognizable. After the product, concession to leave the factory. After analysis, the folding of the printed sheet after the book and periodic press printing has a folding deviation of 0.5 to 1.5mm; the binding of the bookend after printing and the booklet sometimes have a deviation of about 0.5mm; the deviation of the cutting position when the finished product is cut There is 0.5 ~ 1mm. These are very reasonable and normal deviations, which are not contrary to the quality requirements required in the operation instructions, and also meet the quality requirements of the national books and periodicals. However, in the end, the minor deviations piled up together, and the disadvantage of excessive deviations appeared. And, they all exist objectively, and cannot be solved by adjustment, replacement of equipment and personnel. The problem is that the quality inspection department failed to seriously review the requirements: the sample text from the customer's own is printed in eight-fold digital format, only one fold, and the deviation is very small, thinking that other units have already printed it is no problem; Incoming film could not be crossed and checked, and the plaques that should not be bleed are too close to the finished product 2mm, there will be deviations when printing the folding in batches, and it is easy to be cut; the reasonable deviations of each process of binding after printing cannot be taken into account . Finally, according to the production process requirements of the unit, it is decided to change the film, pull open the blank page head 1mm, the folding width changes from a height of 297mm to 298mm, the post-printing processing requirements are basically unchanged, and the cutting position and the flexible adjustment according to the specific circumstances are required. Size, when the second batch of 300,000 copies were printed, only twenty copies of the Chinese characters in the Tiantou book were cut, which basically met the quality requirements and successfully completed the printing task. [next] "Four Fears": Series Book Printing In the printing of textbooks, there are many series of books. In order to facilitate management, publishers often send books of the same variety to the same book printing company for printing. It is certainly a good thing for a printing company to get more orders, but it is not necessarily a good thing to get a series of books. Series books with almost the same content are printed at the same time, which may be a chore. After all, there is a great chance of making mistakes. . For example, a variety of textbooks are issued in the province and abroad, and are entrusted to be printed in our factory. A total of 200,000 copies are printed. The format, printed sheet, cover, text content, printing order, printing color, and paper are the same, only The digital content of a line of the copyright page of the Chinese text is slightly different, with 01, 02, 03, 04 representing: the provincial normal version, the provincial free version, the provincial extra version, and the provincial free version, unlike the previous special on the inner cover or cover. This requirement has not been effectively implemented in the entire printing and production process, but it is simply indicated on the production summons, which failed to attract the attention of the quality inspection, printing and post-printing departments. It was only found that everything was mixed up, and only employees of the whole factory could be mobilized to open packages and turn pages and check them one by one, which was labor-intensive and time-consuming. Of course, the responsibility lies with the book and printing companies, strengthening management, and implementing it in place is a guarantee mechanism for good production, but it is not easy to stay awake during the busy printing season. "Five fears": improper cover decoration process In the printing of teaching materials, sometimes the improper cover finishing process will cause a lot of trouble in the printing and use of books. Taking the format of 16 as an example, the publishing house requires 120 ~ 128g / m2 coated paper for the cover of less than 4 printed sheets, and 157 ~ 200g / m2 coated paper for the cover of more than 4 printed sheets. In order to improve the durability of the teaching materials, for the sake of so-called environmental protection, the publisher requires that the cover be changed to a comprehensive coating. This change greatly increases the difficulty of production from the perspective of the printing plant, especially the wireless binding paper for under 4 sheets is considered to have a lower limit of 120g / m2. The coated paper is lighter and thinner and easily curled after being irradiated with UV light 3. With static electricity adhesion, it is wasteful to wrap the cover on the machine. According to the author's statistics in recent years: glazed covers cost 100% to 200% more in terms of book cover than similar covers with or without film coating, whether it is saddle stitching or wireless plastic binding. The additional increase in production costs cannot be ignored and should be highly valued. In addition, the 120g / m2 paper, especially the domestic coated paper, due to inadequate manufacturing process, unstable quality, poor stiffness and softness, the cost in the glazing processing production link is also quite large. From a practical point of view, the glazed cover can only protect the cover imprint. It does not have the wear resistance, tear resistance, and tensile resistance of the film cover. It protects the long-term durability of the textbook. One or two weeks after the new book is in the hands of the students Most of the covers may be torn or torn by the students carelessly, and some glazed covers are unstable due to the varnish composition, leaving an unpleasant odor, parents will turn to the printing and printing companies to complain, let the books and periodicals Printing companies are very difficult, after all, books and periodicals printing companies are only processed according to the order, and the decision is still the commissioned publishing house. From the process point of view, the emerging coating technology has abandoned the original traditional harmful hot-pressing coating process, and changed it to an environmentally friendly, room temperature, odorless, and non-hazardous aqueous coating process. The cover after coating is not easy Affected by the external environment, it is flat and clean, without static adhesion, which is suitable for the requirements of package production. As the dual identity of the printing practitioner and the parent of the student, the author is far better than the comprehensive glazing in the finishing of the cover of the teaching material. Ningbo XISXI E-commerce Co., Ltd , https://www.petspetsaccessories.com