Author: Wang Huai beads
In recent years, with the acceleration of the publishing rhythm, the number of books using paper-based wireless adhesive binding has been increasing. According to incomplete statistics, the number of books and periodicals printed in China in the past two years has been approximately BO billion, of which more than 40 Billions of books are processed into books by wireless binding. The thermal bonding material EVA hot-melt adhesive used for bonding books and periodicals uses nearly 10,000 tons per year; there are more than 100,000 units that use such adhesive materials for book binding; the wireless adhesive binding equipment is only available in conjunction with the production line. Hundreds, more than 2,000 single machines. There are so many books processed by glue binding technology, and the large amount of dry materials used, which involves a wide range of processing units, is unprecedented in the history of book binding. However, it cannot be seen from the book quality inspection in recent years that the quality problem of book binding is also more serious. According to the relevant part, the unqualified products of binding account for about 65% of the total print quality problems, of which wireless adhesive The unqualified products caused by the order processing accounted for more than 8O%. The unqualified products mainly reflected from the surface that the pages of the books and periodicals appeared after processing, the back of the book was uneven, the book block was broken, the air bubbles, the holes, the overflow of glue, etc. Where does the reason come from? Now we analyze from the following points, so that the relevant units can find out the reasons in the actual management work, be resolved, and improve the quality of wireless binding processing.
Poor understanding of the importance of changes in the post-press binding process
The post-press binding process is the final decoration process of the entire process of the printed product and the final completion process of the book processing. It is related to the use value preservation value and reading value of the printed product, and affects the above two processes (pre-press, printing) Guarantee of processing effect and cycle; no matter how good the printed product is, there is no correct and firm connection, beautiful outer packaging. It also does not reflect the value of the printed matter. Post-press binding is a very important process in the final packaging of printed products.
For a long time, people have always been prejudiced against this process, thinking that everyone can do it, and neglected its importance. At the same time, it has also caused the cultural quality of the people who have been engaged in this work for many years to be lower than the pre-press and printing processes. As one of the largest printing professional institutions in Asia, such as Beijing Printing Institute, there has not been such a special subject that accounts for one-third of the total printing industry in several years. It is only in recent years that there are some post-press binding courses (in the Department of Packaging and Decoration) . In large-scale printing information conferences, printing research conferences generally talk about pre-press and how to print. For example, only the pre-press and printing process can complete the mission, and the books can be read without being assembled into a volume. This situation will continue, can the quality of book binding increase? The high quality of book decoration will affect the overall image of book publishing in China, so it must really attract attention.
Post-press binding is a processing procedure with complicated equipment, complex technology, many kinds of materials, and large changes; as far as equipment is concerned, there are dozens of types, more than 100 models and forms, and there are nearly 10 types of linkage production lines. Each line has different models and forms, and the stand-alone equipment between the types of work has almost no commonality. Post-press binding has gradually evolved from a manual operation process to a modern processing process of mechanized, linked, and automated equipment.
The post-press binding process is more complicated and changes greatly. There are more than 10 kinds of binding methods alone, and some of the binding methods have more than 30 process flows. And the process changes a lot during processing. The publisher needs to process as much as required. Few people pay attention to whether they can meet the requirements.
There are hundreds of types of binding materials, and each kind of material involves a lot of knowledge. For example, there are more than 10 cover materials, and the textures are different. These different materials also involve the use of bonding materials. However, the difference of the deadwood family is related to the object of the deadwood and the firm effect of the deadwood. The correct use of materials directly affects the firmness and shelf life of books. At present, the quality problems that occur in wireless adhesive bonding are directly related to the use of EVA hot melt adhesives.
In short, the post-press binding process is not only a complex processing process but also an art processing process. Today's books are not only reading materials, but also gifts, works of art, and valuable preserves. It not only adds knowledge to humans, but also Bring people artistic enjoyment. Therefore, the effect and value of printed products must be shown by the quality of the binding after printing. For our staff engaged in book publishing, production and other aspects, we must clearly re-understand the complexity, importance and overall concept of making a book, and re-recognize and understand this process for publishing high-quality books. .
The equipment has changed, the personnel quality has not changed
Modern post-press binding equipment has entered a period of mechanization, automation, and linkage production, especially after the early and mid-1990s, China has entered the third period of change in binding equipment, which is characterized by everything moving closer to international standards. At present, there are about 100 large-scale linkage production lines in China, and the price of the most advanced linkage line is nearly 20 million yuan; computer control, image display, etc., the equipment is getting higher and higher, and the management and operation of these equipment require a certain level of technology Management and operation personnel are competent. However, it is understood that there are currently very few talents in this area in our country, and the existing skilled workers are far from meeting the expected requirements; generally, the equipment is coming. Besides, some units only train personnel for a few days and let the machine operate. Most of the equipment comes from the equipment, so the machine can be turned around. Therefore, the life of the equipment is shortened, the efficiency cannot be improved, and the quality of the finished product does not meet the standard requirements. Human factors; as far as the quality of the post-press binding process team is concerned, most of them are not graduated from professional schools, and have not even received any training. How can they adapt to modern production today? The equipment has become advanced, and the quality of people has not changed. How can we keep up with the trend of the times?
Process materials have changed, environmental conditions have not changed
As far as the wireless glue binding process is concerned, almost every book processing plant has to be involved. The vast majority of the drilling materials used in this process are thermoplastic EVA hot-melt adhesives, and the requirements for the environment and conditions of this thermoplastic bonding material are very strict when used. At the "Sino-German Bookbinding Technology Training Course" organized by Nanjing Aide Printing Co., Ltd., German teacher Mr. Stahl presented the importance of environment and conditions when explaining the use of EVA hot melt adhesive, and introduced the EVA hot melt adhesive in France. The temperature and humidity in the workshop where the booklet is processed are controlled by certain data. Among them, the temperature is controlled between 19 ℃ -25 ℃, and the humidity is controlled around 50% RH; while China generally requires the temperature in the wireless binding production workshop to reach 17C-30C Between; this requirement is twice as bad as abroad. However, except for a few units and regions that can meet this requirement, most of them can not be implemented according to this requirement. For example, the temperature in southern China is high, and many unit binding workshops do not have workshops that use EVA hot melt adhesives when the temperature is constant or the air conditioner has the highest temperature. The temperature is as high as about 38 C, which causes the curing time to extend after the glue is applied, does not harden and set, and the linked production line cannot be cut. When the winter temperature in the north is low, the indoor temperature is the lowest (no constant temperature, air conditioning equipment) to about 10C, which causes the hot melt adhesive to be cured in advance and cannot be bonded ... As for the temperature, it varies by dry area. The standardization of the enterprise is not perfect (there is no hygrometer device in the general binding workshop), and the requirement to reach the expected humidity standard is even more slim; for example, in the south of China, where the rain is heavy, the humidity is high, the humidity in the workshop is about 80% RH, while the north The rain in the area is less dry, and the minimum humidity can reach about 30% RH. If the humidity is too low or too high, it will have a direct effect on the binding and setting effect of paper and books, and will cause various quality problems of wireless adhesive bookcases.
In order to improve the quality of book binding. In the binding workshop, especially where hot melt adhesive materials such as EVA are used, a good environment and conditions must be created to implement standardized production.
Inadequate understanding of modern bonding materials
There are two kinds of binding materials used for binding, one is cold water sol; the other is thermoplastic adhesive, which can be divided into permeable type, attractive type and semi-adhesive type after being qualified by hot melt. Permeable type (also called semi-attractive type), the bonding materials used in these three forms are different from the types of objects to be bonded, and the bonding effect is also different.
China's binding adhesive materials have used cold glue for a long time, cold glue is a water solvent, and its drying method is to set the shape with the temperature and time after heating and pressing. The thermoplastic adhesives commonly used in modern times are different, such as EVA hot melt adhesives, which are a solid, moisture-free fusible adhesive dry material, the use of this material should pass the appropriate melting point (softening) temperature, use temperature , Opening time, solidification time and cooling hardening time, and then the correct clamping and shaping, can achieve the reliable effect of dry knot. Because EVA hot melt adhesives are affected a lot when they are used, such as the temperature and humidity of the plant, the speed of the operation, the texture of the paper, the different backing and side adhesives, the temperature of the adhesive, etc., are all related to the processed products. Pros and cons have a direct relationship.
In addition, many publishers require that the thickness of the backing glue of the processing plant should be as large as possible. It is believed that the more the backing glue is applied, the stronger it is. This is a misconception. In fact, the fastness of the book connection is in a certain sense. Firmness does not matter. Because the strength, viscosity, viscosity, etc. of the adhesive can determine the book fastness. As long as the strength, viscosity, viscosity, etc. of the book back adhesive meet the standard requirements, the adhesive layer should be "thin and uniform": if the book back adhesive is applied too thick, it can only cause the back of the book to be uneven, difficult to read, ugly appearance and wasted rubber.
There are many types of cold and hot adhesives for binding materials. Among them, EVA hot melt adhesives have different bonding effects due to different sources of basic materials, different types of auxiliary materials and the price of various ingredients, and different models. Therefore, we must fully understand the various materials (including cover materials, cardboard, etc.) that are out of use in modern times, strengthen the study, clarify the theory and then apply it to practice, record the use experience at any time and summarize it, and the ascending theory cycles in turn Improve to meet the ideal requirements.
There is little communication between the designer of the publishing house and the bookbinding factory
In the past few decades, the publishing industry has engaged in design (especially American editing) personnel and binding technicians. The teacher pays attention to the advice of the bookbinding workers to improve and enhance the design plan to achieve the consistency of the design expectations and product completion (that is, the imagination and the destination). Made many high-quality products that won various international and domestic awards. There are many well-known artists of American editing. They take the initiative to make friends with the binding factory and masters, learn the binding process from them, and learn about various binding techniques to better design more excellent works. But in recent years, there has been too little such communication. At present, some younger American editors generally only pay attention to the news on the computer, and do n’t go to the factory to understand and learn the knowledge that is not available on the computer from the masters, and forget the practice. Be truthful. Others think they are designing and are artists of the future. When they go to the factory to learn from the workers, they can't put down the shelves, etc., which makes them suffer a lot and lose a lot of knowledge. Therefore, there are many problems in the design, the size of the materials, etc. The following are a few phenomena:
1. Regardless of the value and effect of the bibliography, blindly pursuing wireless glue binding processing
The use (reading) value and preservation value of books are directly related to the correct selection of binding process methods and types of binding materials. In general, if there are high-end books with preserved value, you should choose a long-term exquisite installation process; the binding material must also match the special grade of the book to obtain the desired effect. Generally, the books can be processed through the general installation method; simple and short use time For the books and periodicals, you can choose the simplest method. However, we can see from the book market and the situation of book publishing nationwide that the number of cases of wireless glue binding. It currently accounts for more than 60% of the total number of books installed. The author does not deny that wireless adhesive binding has many advantages, such as fast book publishing, short cycle, suitable for modern rhythm, and low labor and material cost. However, this processing method also has many deficiencies, such as â‘ It is aging and not easy to store for a long time; â‘¡Thick books are not easy to read and change: â‘¢The bonding is not strong, and the pages are easy to fall or break, which has become the most binding method for book binding quality problems.
However, in order to publish books eagerly and want to reduce costs, some publishers should use the thick thick books that are booked in soft volumes or processed in hardcover to make a thick paperback wireless adhesive book. As a result, the two parties were confused. There is a publishing company in Hebei Province who is going to make a book with a size of 32K (A5) and a thickness of 4Bmm. I indirectly asked the author if it is possible to process wireless perfect binding paperback? The author replied at the time: "No! Either do hardcover, or do 2-3 volumes of wireless bound paperback ..." As you can imagine, for example, such a thick book is really a wireless bound paperback, and the result is ; A, unable to read (can't read without holding down); B, uneven front cut, and stand out of the belly to become a rounded round; C, the appearance of the whole book is changed; D, the page is broken, the core of the book is broken; E, Withering can not be firm, shorten the life of the book, and cannot be stored for a long time.
China is the earliest binding technology in the world, and it is also the binding method with the most styles. In the oldest countries, there are more than 10 types of installation methods, and there are currently 4 or 5 types of installation methods commonly used, with a wide range of choices. However, according to the current situation, it is really not normal to use wireless perfect binding for paperbacks. Of course, it should be used, but do n’t use it if it should n’t be used, and it will eventually cause trouble and prevent good and valuable books from being properly saved and used.
2. Numerous problems caused by cover material selection and design
There are many books that do not consider the processing difficulties and effects on the cover material selection, causing various quality problems. One or two examples are listed below for your analysis.
â‘ The cover quality is different from the paper thickness of book blocks. In order to improve the effect of book loading and framing, there are many books whose cover thickness differs greatly from the thickness (or weight) of the book block paper, resulting in unequal tension between the two. When the cover is lifted after wireless binding, the book block is pulled out one page to expose The glue bottom or sample pages cause unqualified products, and there is a conflict between the publisher and the processor. This kind of product can solve the problem of bottom leakage if a moderate weight (thickness) ring liner or title liner is added between the cover and the first page of the book block, but many publishers do not intend to do so at all to reduce costs. The processing effect is not considered.
â‘¡The crease of the cover paper material is not properly broken. Now the thickness of the cover is getting larger and larger. The cardboard or paper above 200 grams is designed with a folding front opening process. When the creasing is broken, the crease breaks and the bottom is leaked, which destroys the appearance quality of the bookcase. In fact, the front cover of 200g or more needs to be folded, so the book binding process is very difficult, and the quality cannot be guaranteed, so it causes quality problems.
â‘¢The length of the cover is shorter than the length of the book block, resulting in dirty books. During book binding processing, most of the cover length is about 7mm shorter than the book block. As a result, the end of the book is empty when the wireless binding is applied, resulting in a dirty book leaking from the exposed part of the book back. This phenomenon can be completely avoided if the head and the burrs of the feet are left in the cover design.
④The design pattern leaves no room for processing. Other beauty editors do not take into account the design, the cover of the frame does not take into account the difficulties in the binding process, and does not understand the quality requirements of the binding, and deliberately pursues the appearance of beauty, resulting in the expected effect when binding. For example, if a processing unit receives a paperback book from a publishing house, the thickness is 12mm. The back of the book, which is designed with its cover, is divided into black on all white. The full version of Feng Yi and Feng Si is black and white, which requires the processing plant not to expose the cover on the cover during processing. This requirement is too difficult. According to the national CY / 128-1999 binding quality requirements and inspection methods paperback "3, 4, 5 regulations: the back of the book translation error is subject to the center line of the back of the book, the thickness of the back of the book is less than 10mm, the back of the book translation tolerance is ≤1Omm; the book back thickness is greater than 20mm and less than or equal to 30mm, the book back word translation tolerance is 2.5mm; the book back word thickness is more than 30mm, the book back word translation tolerance is 3.Omm. The book back word is skewed The tolerances are all 0.5mm smaller than the tolerance of the translation of the back of the book. So how can this kind of black and white design achieve the desired results for the demanding requirements of the processor? There are too many examples. I hope that the publisher will be bound with the binding The processing unit knows more about constant communication, correctly understands the overall concept of a book, and works together to make a book well.
Cultivation of unfocused talents
After the market economy, competition in all walks of life is very fierce, and there is a lot of life and death, and the focus of competition is nothing more than eight characters, namely "talent, quality, equipment, reputation", and first of all, talent, with technology and business talent, Still afraid of not producing good products? However, in the analysis of the situation of binding this major, because of the poor foundation of cultural quality, and there is no vocational school for training this professional and technical personnel, even finding a professional teacher is very difficult. According to the complexity and variability of this major, it is impossible to adapt to modern development without putting talents in this area on the agenda.
It is understood that there are more than 100,000 training factories and binding workshops in the country, and the staff engaged in binding accounts for I / 3 of the total number of 3 types of work (pre-press, printing, post-press) in the entire printing industry. Such a large professional team, There is a serious problem of talent training, which is very undesirable. Several phenomena are listed below for your understanding.
1. Personnel are not trained. It is understood that there are more than 100,000 wage earners (sisters) who do bookbinding in the country, and there are thousands of them in the suburbs of Beijing alone. They work as soon as they enter the factory. They do not study or train. Not even the master.
2. Some companies will cultivate talents and improve product quality. They would rather spend money and ask customers to forgive them for dinner, and do not want to spend money to train workers to learn technology to be effective.
3. Some enterprise leaders and bosses dare not train workers to learn technology, and understand that "there is a job change after training."
4. There are some leaders who do not want to let workers go out to study during their term of office, fearing that they will be re-elected to "cook and eat" for the next leader.
With such thoughts and practices, how can we improve the quality of workers and cultivate talents to improve product quality?
In short, the various quality problems that occur in post-press binding, especially the page breaks reflected in wireless glue binding in recent years, uneven backs, wrong posts, broken book cores, etc., are all appearances. The root cause comes from There are many aspects, so we must fundamentally understand, treat, research, and propose solutions, so that we can catch up with the pace of society and truly receive results in improving product quality.
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