Application and development of roll-to-roll automatic photoelectric roll in packaging and printing industry

Working principle and key technology

The operation of roll-on-roll automatic photoelectric roll equipment is based on a set of precise and efficient working principles. It uses continuous roll materials as carriers, and starts from the unwinding unit, through a precise tension control system to smoothly unwind the roll materials. In this process, the stability of tension is very important, because even the slightest tension fluctuation may cause problems such as wrinkles and stretching deformation in the subsequent processing of the material, which in turn affects the accuracy of printing and processing. For example, in label printing, if the tension of the material is uneven when unwinding, the printed text and pattern may be distorted or positionally deviated, seriously affecting the beauty and readability of the label. ​
After entering the printing or processing unit, a variety of advanced technologies come into play. Taking the common inkjet printing technology as an example, the equipment uses a computer-controlled nozzle to accurately spray ink onto the surface of the material to form the required pattern and text. In the processing of packaging cartons, laser die-cutting technology can quickly and accurately cut complex carton shapes through high-energy laser beams. In order to achieve high-precision printing and processing, the equipment is equipped with an advanced photoelectric detection system. During the printing process, the electric eye alignment system can detect the color mark in real time. Once the printed pattern is found to deviate from the preset position, the system will automatically adjust the position of the nozzle or printing plate immediately to ensure that the overprint accuracy reaches the micron level. This high-precision control capability is essential for the production of products such as high-end cosmetic packaging that require extremely high pattern exquisiteness and printing accuracy. ​
After the printing or processing is completed, the drying or curing unit intervenes quickly. For products printed with UV ink, UV curing technology uses ultraviolet rays of a specific wavelength to cause the photosensitive components in the ink to polymerize instantly and achieve rapid curing. This not only greatly shortens the drying time and improves production efficiency, but also effectively avoids the problems of ink flowing and smudging that may occur during the drying process, ensuring the clarity and color vividness of the printed pattern. In the printing of plastic film for food packaging, UV curing technology can quickly cure the ink on a high-speed production line to ensure that the ink is firmly attached to the film during subsequent lamination, slitting and other processing processes, and does not fall off or fade. ​
Finally, the winding unit neatly winds up the processed rolls. Similarly, the tension control during the winding process cannot be ignored. It is necessary to ensure that the wound material is tight and flat, and avoid loose rolls or curling, so as to facilitate subsequent packaging, transportation and storage. ​
Significant advantages​
Efficient production and improved production capacity: Compared with traditional single-sheet printing and processing methods, the roll-to-roll fully automatic photoelectric winding equipment adopts a continuous production mode, which greatly improves production efficiency. In the label printing industry, traditional single-sheet printing machines may only print hundreds of labels per hour, while roll-to-roll fully automatic printing equipment can print tens of thousands of labels per hour, and the production efficiency has increased by dozens of times. In the production of packaging cartons, continuous roll material processing combined with high-speed die-cutting and folding processes can quickly produce a large number of cartons with consistent specifications to meet the production needs of large-scale orders. This efficient production capacity enables enterprises to complete order delivery in a shorter time and enhance market competitiveness. ​
High-precision processing to ensure quality: With the help of advanced photoelectric detection and automatic control systems, roll-to-roll fully automatic photoelectric winding equipment can achieve extremely high processing accuracy. During the printing process, through precise electric eye alignment and automatic adjustment mechanism, the overprint accuracy of the printed pattern can easily reach the micron level. This is especially important for the production of packaging products that require exquisite patterns and precise text information. In the printing of high-end gift packaging, high-precision printing can perfectly present delicate pattern details and bright color levels, enhancing the visual appeal and quality of the product. At the same time, in the processing of packaging structure, the high-precision control of the equipment ensures the dimensional accuracy and folding accuracy of the paper box, making the packaging more fit to the product during use and better protective performance. ​
Save manpower and reduce costs: The highly automated nature of the equipment requires only a small number of operators to monitor and maintain it during operation, and most of the work is done automatically by the equipment. This not only reduces the errors caused by manual operation, but also significantly reduces the labor costs of the enterprise. In some areas with high labor costs, companies that use roll-to-roll fully automatic equipment can effectively control production costs and increase profit margins. Taking the production of plastic packaging bags as an example, the traditional production method requires a large number of manual operations such as printing, cutting, and edge sealing, while the roll-to-roll fully automatic equipment can integrate these processes to achieve automated production, greatly reducing labor input. ​
Flexible and diverse, strong material adaptability: The equipment has excellent material adaptability and can handle many different types of packaging materials, including plastic film, paper, metal foil, etc. Whether it is soft PET film used to make food packaging bags or hard cardboard used to pack paper boxes, the roll-to-roll fully automatic photoelectric roll equipment can automatically adjust the parameters such as printing, processing and drying according to the characteristics of the material to achieve high-quality processing. In the packaging and printing industry, customers' choices of packaging materials are becoming increasingly diverse. This wide range of material adaptability enables companies to better meet the needs of different customers and expand their business scope. ​
Green environmental protection, sustainable development: In the drying and curing process, if UV curing technology is used, energy consumption can be greatly reduced compared with the traditional hot air drying method. At the same time, no volatile organic compounds (VOCs) are produced during the UV curing process, which is more environmentally friendly. In addition, the automated operation of the equipment reduces material waste, further reflecting its environmental protection and energy-saving characteristics. In the context of increasingly stringent environmental protection requirements in today's society, the green characteristics of the roll-to-roll fully automatic photoelectric roll equipment make it an ideal choice for packaging and printing companies to achieve sustainable development. ​
Specific applications in various sub-segments of packaging and printing​
Label printing: In the field of label printing, roll-to-roll fully automatic photoelectric roll equipment is extremely widely used. Whether it is food and beverage labels, daily chemical product labels, or electronic and electrical product labels, high-quality printing can be achieved through this equipment. The equipment can print clear and exquisite patterns and texts on various label materials, such as paper labels, self-adhesive labels, film labels, etc. In the printing of food and beverage labels, it is necessary not only to ensure the beauty of the pattern, but also to meet the printing standards related to food safety. The roll-to-roll equipment can ensure that the information such as the nutrition information table and production date on the label is clear and easy to read through high-precision printing and the application of special inks, and the ink meets the food contact safety requirements. At the same time, the equipment can also realize personalized customized printing of labels to meet the diversified marketing needs of enterprises. ​
Packaging carton production: For the production of packaging cartons, the roll-to-roll fully automatic photoelectric roll equipment provides a one-stop solution from cardboard printing, die-cutting to folding. In the printing process, various exquisite patterns and brand logos can be printed on the cardboard to enhance the visual appeal of the product. In the die-cutting and folding process, the high-precision control of the equipment ensures the dimensional accuracy and folding accuracy of the carton, making the assembly of the carton more convenient. For some packaging boxes with complex structures, such as special-shaped cartons and window cartons, the roll-to-roll equipment can complete the processing efficiently and accurately through advanced laser die-cutting and automatic folding technology. In the production of high-end tobacco and alcohol packaging cartons, roll-to-roll equipment can achieve delicate pattern printing and exquisite packaging structure production, improving the grade and added value of products. ​
Plastic packaging bag manufacturing: In the manufacturing process of plastic packaging bags, roll-to-roll fully automatic photoelectric roll equipment plays a key role. It can print various patterns, texts and product information on plastic films with high precision. Then, through processes such as heat sealing and cutting, the printed film is made into plastic packaging bags of various specifications. In the production of plastic packaging bags for food packaging, the equipment must not only ensure the exquisiteness of printing, but also ensure the sealing and barrier properties of the packaging bags. Through advanced heat sealing technology and material composite technology, roll-to-roll equipment can produce food packaging bags with good freshness, moisture resistance and oxidation resistance, extending the shelf life of food. At the same time, in terms of personalized customization of plastic packaging bags, the equipment can also meet the diversified needs of enterprises, produce packaging bags with unique designs, and enhance the recognition of products in the market.