Plate making is a crucial step in the production of corrugated boxes, and it typically involves several techniques such as manual engraving, laser engraving, flexographic printing, lithographic (PS) printing, and die-cutting. These methods are widely used in the corrugated box industry, with the choice of technology often depending on the size and capabilities of the enterprise. Small carton manufacturers tend to rely on manual engraving due to its low cost, although this method requires skilled personnel and is becoming less common. Despite its decline, it is still used in some small-scale operations, particularly in certain regions like the Midwest.
Laser engraving for flexographic plates (rubber versions) has become popular among manufacturers looking to reduce costs, especially for small batch or irregular orders. This technique is more efficient and easier to manage, requiring only a computer and a laser engraving machine. The process starts with designing the layout on a computer, then transferring the design to the laser machine, which engraves the plate according to the digital instructions. After engraving, the staff must clean up the layout, remove unnecessary parts, and verify the final product against a sample before handing it over to the production team.
For die-cutting plates, many companies outsource the work to specialized plate-making firms. This approach offers faster production, higher precision, and longer durability, but it also comes with higher costs and slower tool changes. Some companies still use manual methods, where designers create layouts on computers, manually cut the plates, and install knife lines by hand. While this method is still practiced, it is inefficient, error-prone, and rarely used today.
Dry flexographic plates (resin versions) involve a more complex process. Layouts are designed on a computer, and a proof is printed for customer approval. A negative film made from sulfuric acid paper or film is placed over a resin base plate, which is then exposed in a dedicated machine for about 30 minutes. After exposure, the plate is washed, baked, and debonded. Once completed, it is reviewed by a designer before being sent to the production department.
Lithographic (PS) plates are usually handled by professional design and plate-making companies. This method includes color separation proofs, ensuring that the printed colors match the samples exactly. Plate-makers must carefully control exposure time and maintain clean equipment. The process involves preparing the plate, positioning the negative film, exposing the plate, developing it, and finally cleaning and trimming it before delivery to the production line.
In summary, the plate-making process varies significantly depending on the company’s size, resources, and needs. While modern technologies have improved efficiency and accuracy, the choice of method should always align with the specific requirements of the business. As the industry evolves, it's important for manufacturers to adapt while maintaining quality and cost-effectiveness. Some large enterprises may invest in advanced proofing equipment to speed up the process, but for most, a balanced approach remains the best strategy.
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