The prepress revolution brought about by CTP technology has brought great profits to early investors. As CTP becomes more and more mature today, with the increase in material costs, labor costs, and price increases, printing companies have brought a lot of pressure. The new round of CTP buyers no longer just focus on technology and processes. What they are thinking about is how to effectively reduce the cost of use and improve efficiency. Of course, as a sensible buyer, there must be a full preparation for the operation of the CTP. The cost of laser head replacement, equipment maintenance, and downtime they consider is also necessary. This article will also be from another perspective: CTP. The cost of equipment after-sales maintenance costs, how to effectively reduce the cost of CTP maintenance and the importance of CTP maintenance, for you to interpret CTP maintenance solutions.
First, the cost of CTP maintenance costs
More CTP investors in the beginning of the understanding of the CTP, more than just the CTP laser head as an important part of the use of the process to calculate maintenance costs, so often worried about the loss of the laser head after purchase to increase maintenance costs, The true cost of maintenance includes the following aspects:
1. Part cost refers to the cost of CPT equipment that needs to be purchased in the event of a failure. Basically, it includes the laser parts, circuit parts, and mechanical parts of CTP equipment.
2. The consumables cost refers to some loss parts that need to be replaced on time according to the CTP equipment during use. For example: air filter, dust filter, detection and control.
3, maintenance service fee refers to the costs incurred during the maintenance process, including the costs incurred by their own factory maintenance personnel or outsiders.
4. The cost of downtime is the cost of CTP machine downtime, which is usually not included in the maintenance category, but can be used as a reference for cost calculation.
Calculated in this way, if a commercial printing company is involved, and it is divided into 2 to 3 shifts and 24 hours of work, a single machine counts 22 sheets per hour, and the volume is about 120,000 copies in one year, within a year in the CTP machine. Under normal operating conditions, the cost of the required consumables is roughly: 1,722,200 yuan.
Some calculations, some customers will scream, and the cost of one of our CTP is far more than these, if the user's all maintenance depends on the supplier to operate, you may need to pay higher fees. However, most suppliers now prefer to sign the relevant maintenance contract to provide services, so as to provide more time and technical protection. Even so, it is necessary to talk about the following common issues and maintenance related content related to CTP.
Second, the common problem of CTP machine
During the use of the CTP machine, due to its compact structure and good design, the problem is generally relatively small, but long-term actions inevitably have some problems. The following common problems are listed as follows:
1. Into the system failure, most of the CTP's version of the system is the use of pneumatic devices to operate, the pneumatic part includes the machine's protective door, platen roller, platen clips, platen clips and other devices, pneumatic Partial adjustments Most customers can complete their own, and even some parts customers can also replace it.
2, the failure of the exposure process, the relative mechanical action, the failure occurred during the exposure may be tricky, but as long as careful analysis is not difficult to find the problem of disease, we can according to the thinking analysis: the plate itself, failure, Failures in the development process, document problems, problems in the exposure process, and human problems, etc., to find problems to solve problems.
3. Problems of the circuit and the sensing part. Circuit problems usually include the guidance and storage of data by the software. The sensing part is the detection of all actions and safety protection devices. Most of the error information of the machine can indicate the core part of the problem. With solutions and solutions, customers can solve problems by themselves or by contacting relevant technical personnel.
4, laser part of the problem, laser problems are mostly reflected in the output of the plate, usually through adjustment can be resolved, and if it is caused by temperature and humidity problems, customers can also solve their own, if it is really very small If the laser internal circuit fails, it needs to be replaced.
5, the lower part of the failure, and the upper part of the same version, the lower part of the sub-automatic and manual, most of the mechanical action and some of the location of induction, as long as the usual more maintenance will not be a major failure.
The general parts of the above-listed common problems are also reminding customers that a stable CTP system needs careful maintenance. Good maintenance includes:
Third, CTP maintenance content
Through routine and planned cleaning, lubrication and proper adjustment of equipment maintenance, equipment maintenance costs can be minimized. The maintenance of CTP equipment is mainly reflected in the following aspects:
1. Comply with safety operations and strictly follow the physical and chemical safety operations of the equipment to eliminate unsafe factors.
2, appropriate lubrication, good lubrication can effectively improve the operation part, especially the CTP screw and slide, must be regularly added with qualified oil products.
3, finishing the relevant connection line and inlet, drainage and other devices, if all the connected components can work properly, it must be able to ensure the normal operation of the entire system.
4. Clean the internal and external positions of the machine. Cleaning is the first of all maintenance contents. Because of the dust of the laser burning candle inside the CTP machine, the attachments of each roller will inevitably increase the load of the machine. Therefore, cleaning is especially important in the use of CTP.
5, properly adjust the environment temperature and humidity, temperature and humidity are critical for CTP machines, high temperatures easily lead to accelerated aging of the thermal laser head, humidity is too high on the plate and the internal cleaning of the machine is quite unfavorable, so CTP The machine is best used within the specified range of temperature and humidity. In case of abnormal temperature and humidity, it is recommended that you quickly adjust the environment, the normal CTP room temperature is 20±2°C, and the humidity is 50%±10. The comfortable environment can not only guarantee the machine The normal operation can also make the product quality stable.
6, to ensure the normal input voltage and pressure, clean and stable voltage and pressure is the primary condition for the healthy operation of the machine, the input voltage of each circuit and switching power supply can ensure the normal operation of the circuit board, and pressure stability can make the laser head energy Effective dedusting also enables all moving parts to maintain good operation.
Of course, during the use of CTP, it is more important for each company to formulate relevant maintenance content according to its own needs.
Fourth, the importance of CTP equipment maintenance
The daily maintenance of the equipment is the basic work of equipment maintenance. Its importance is directly reflected in its production value. In the long-term maintenance of the CTP site, it is found that most people think that the thermal laser head has a life of 3000-5000 hours, and it is in good condition. In the environment, the thermal laser head has been used for more than 10,000 hours. It is absolutely good that these tens of thousands of hours of the laser head are in the environment, plus the good quality of the CTP operators. Not only has the problem been solved in time, but more importantly it has reduced the cost of maintenance and repair, thereby increasing the efficiency.
Cooperation with suppliers can not only improve the skills of CTP operators, but also learn about the performance of the equipment during the learning process, which in turn can be used to control CTP machines. Currently, for the CTP market, most of the supply can provide customers with good services. And a variety of solutions, such as: Kodak company provides remote diagnosis, 800 free telephone and network technology support platform, etc., are to provide customers with meticulous service care. So when the machine has a problem, we need to consult a more professional staff to deal with it, rather than waste the maintenance time.
On the other hand, many merchants only purchase one CTP device, and if the negligence in maintenance results in the shutdown of the entire flow printing process, such losses will be even greater. Here, we must also remind CTP managers that the meticulous maintenance of CTP equipment depends on the operator to complete and execute. Only the correct use of equipment by operators can maintain the equipment's good performance, make full use of equipment efficiency and prolong its service life, while reducing or Avoid sudden failures, and don't rely solely on solutions that come out of trouble.
When you determine the purchase of CTP equipment, pay attention to the equipment to bring you benefits, but also pay attention to your maintenance plan will be paid by the equipment, through daily maintenance and continuous accumulation and summing up the lessons learned, to cultivate awareness of protection, rely on the initiative The maintenance method can prevent failures and reduce losses to the maximum extent, so that the CTP equipment can really exert long-term and high-yield.
First, the cost of CTP maintenance costs
More CTP investors in the beginning of the understanding of the CTP, more than just the CTP laser head as an important part of the use of the process to calculate maintenance costs, so often worried about the loss of the laser head after purchase to increase maintenance costs, The true cost of maintenance includes the following aspects:
1. Part cost refers to the cost of CPT equipment that needs to be purchased in the event of a failure. Basically, it includes the laser parts, circuit parts, and mechanical parts of CTP equipment.
2. The consumables cost refers to some loss parts that need to be replaced on time according to the CTP equipment during use. For example: air filter, dust filter, detection and control.
3, maintenance service fee refers to the costs incurred during the maintenance process, including the costs incurred by their own factory maintenance personnel or outsiders.
4. The cost of downtime is the cost of CTP machine downtime, which is usually not included in the maintenance category, but can be used as a reference for cost calculation.
Calculated in this way, if a commercial printing company is involved, and it is divided into 2 to 3 shifts and 24 hours of work, a single machine counts 22 sheets per hour, and the volume is about 120,000 copies in one year, within a year in the CTP machine. Under normal operating conditions, the cost of the required consumables is roughly: 1,722,200 yuan.
Some calculations, some customers will scream, and the cost of one of our CTP is far more than these, if the user's all maintenance depends on the supplier to operate, you may need to pay higher fees. However, most suppliers now prefer to sign the relevant maintenance contract to provide services, so as to provide more time and technical protection. Even so, it is necessary to talk about the following common issues and maintenance related content related to CTP.
Second, the common problem of CTP machine
During the use of the CTP machine, due to its compact structure and good design, the problem is generally relatively small, but long-term actions inevitably have some problems. The following common problems are listed as follows:
1. Into the system failure, most of the CTP's version of the system is the use of pneumatic devices to operate, the pneumatic part includes the machine's protective door, platen roller, platen clips, platen clips and other devices, pneumatic Partial adjustments Most customers can complete their own, and even some parts customers can also replace it.
2, the failure of the exposure process, the relative mechanical action, the failure occurred during the exposure may be tricky, but as long as careful analysis is not difficult to find the problem of disease, we can according to the thinking analysis: the plate itself, failure, Failures in the development process, document problems, problems in the exposure process, and human problems, etc., to find problems to solve problems.
3. Problems of the circuit and the sensing part. Circuit problems usually include the guidance and storage of data by the software. The sensing part is the detection of all actions and safety protection devices. Most of the error information of the machine can indicate the core part of the problem. With solutions and solutions, customers can solve problems by themselves or by contacting relevant technical personnel.
4, laser part of the problem, laser problems are mostly reflected in the output of the plate, usually through adjustment can be resolved, and if it is caused by temperature and humidity problems, customers can also solve their own, if it is really very small If the laser internal circuit fails, it needs to be replaced.
5, the lower part of the failure, and the upper part of the same version, the lower part of the sub-automatic and manual, most of the mechanical action and some of the location of induction, as long as the usual more maintenance will not be a major failure.
The general parts of the above-listed common problems are also reminding customers that a stable CTP system needs careful maintenance. Good maintenance includes:
Third, CTP maintenance content
Through routine and planned cleaning, lubrication and proper adjustment of equipment maintenance, equipment maintenance costs can be minimized. The maintenance of CTP equipment is mainly reflected in the following aspects:
1. Comply with safety operations and strictly follow the physical and chemical safety operations of the equipment to eliminate unsafe factors.
2, appropriate lubrication, good lubrication can effectively improve the operation part, especially the CTP screw and slide, must be regularly added with qualified oil products.
3, finishing the relevant connection line and inlet, drainage and other devices, if all the connected components can work properly, it must be able to ensure the normal operation of the entire system.
4. Clean the internal and external positions of the machine. Cleaning is the first of all maintenance contents. Because of the dust of the laser burning candle inside the CTP machine, the attachments of each roller will inevitably increase the load of the machine. Therefore, cleaning is especially important in the use of CTP.
5, properly adjust the environment temperature and humidity, temperature and humidity are critical for CTP machines, high temperatures easily lead to accelerated aging of the thermal laser head, humidity is too high on the plate and the internal cleaning of the machine is quite unfavorable, so CTP The machine is best used within the specified range of temperature and humidity. In case of abnormal temperature and humidity, it is recommended that you quickly adjust the environment, the normal CTP room temperature is 20±2°C, and the humidity is 50%±10. The comfortable environment can not only guarantee the machine The normal operation can also make the product quality stable.
6, to ensure the normal input voltage and pressure, clean and stable voltage and pressure is the primary condition for the healthy operation of the machine, the input voltage of each circuit and switching power supply can ensure the normal operation of the circuit board, and pressure stability can make the laser head energy Effective dedusting also enables all moving parts to maintain good operation.
Of course, during the use of CTP, it is more important for each company to formulate relevant maintenance content according to its own needs.
Fourth, the importance of CTP equipment maintenance
The daily maintenance of the equipment is the basic work of equipment maintenance. Its importance is directly reflected in its production value. In the long-term maintenance of the CTP site, it is found that most people think that the thermal laser head has a life of 3000-5000 hours, and it is in good condition. In the environment, the thermal laser head has been used for more than 10,000 hours. It is absolutely good that these tens of thousands of hours of the laser head are in the environment, plus the good quality of the CTP operators. Not only has the problem been solved in time, but more importantly it has reduced the cost of maintenance and repair, thereby increasing the efficiency.
Cooperation with suppliers can not only improve the skills of CTP operators, but also learn about the performance of the equipment during the learning process, which in turn can be used to control CTP machines. Currently, for the CTP market, most of the supply can provide customers with good services. And a variety of solutions, such as: Kodak company provides remote diagnosis, 800 free telephone and network technology support platform, etc., are to provide customers with meticulous service care. So when the machine has a problem, we need to consult a more professional staff to deal with it, rather than waste the maintenance time.
On the other hand, many merchants only purchase one CTP device, and if the negligence in maintenance results in the shutdown of the entire flow printing process, such losses will be even greater. Here, we must also remind CTP managers that the meticulous maintenance of CTP equipment depends on the operator to complete and execute. Only the correct use of equipment by operators can maintain the equipment's good performance, make full use of equipment efficiency and prolong its service life, while reducing or Avoid sudden failures, and don't rely solely on solutions that come out of trouble.
When you determine the purchase of CTP equipment, pay attention to the equipment to bring you benefits, but also pay attention to your maintenance plan will be paid by the equipment, through daily maintenance and continuous accumulation and summing up the lessons learned, to cultivate awareness of protection, rely on the initiative The maintenance method can prevent failures and reduce losses to the maximum extent, so that the CTP equipment can really exert long-term and high-yield.
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