The pre-press revolution brought by CTP technology has brought huge profits for early investors. With the increasing maturity of CTP today, with the rise in material costs, labor costs and prices, printing companies have brought a lot of pressure. The new round of CTP buyers no longer only value technology and processes. What they are thinking is: how to effectively reduce the cost of use and improve efficiency. Of course, as a wise purchaser, there must be a sufficient preparation for the early operation of CTP. The cost of laser head replacement, equipment maintenance and downtime they consider is also necessary. The three aspects of equipment after-sales maintenance cost-consuming investment, how to effectively reduce CTP maintenance costs and the importance of CTP maintenance, interpret the CTP maintenance solution for you.
1. The cost of CTP maintenance
At the beginning of understanding CTP, more CTP investors only regarded CTP laser head as an important part in the use process to account for maintenance costs, so after purchase, they often worried about damage to the laser head and increased maintenance costs. The real maintenance cost includes the following aspects:
1. Parts cost refers to the cost of purchasing parts in the case of CTP equipment failure, which basically includes the laser parts, circuit parts and mechanical parts of the CTP equipment.
2. The cost of consumables refers to some consumable parts that need to be replaced on time during the use of CTP equipment. For example: air filter, dust filter, detection control, etc.
3. The maintenance service fee refers to the cost incurred during the maintenance process, including the related costs incurred by the maintenance personnel of your own factory or outsiders.
4. The cost of downtime is the cost of CTP machine downtime, which is usually not included in the maintenance, but it can be used as reference data for cost calculation.
Under normal circumstances, there will be corresponding warranty contracts between CTP suppliers and purchasers, so during the first year of the warranty period, customers can usually sit back and relax. Once the warranty period is over, most customers will worry about equipment failures and cause lost work. And the cost of parts and materials that are actually consumed in the time after the warranty is as follows:
The following data will be slightly changed due to different suppliers, the data according to the standard, the price is for reference only:
Name
Replacement cycle
effect
price
Air filter
Three months
Dustproof inside the machine
180.00 yuan
Dust filter bucket
1 year (according to the condition of the plate)
Remove plate dust
3500.00 yuan
Air filter
Six months
Purified air enters the laser head
450.00 yuan
Water filter
One month
Purify tap water
150.00 yuan
Circulation filter
One month
Prevent dirt from adsorbing on the plate
150.00 yuan
Maintenance accessories
One year
Replacement of aging parts
2500.00 yuan
lubricating oil
Half a year
Increase the lubrication of moving parts
1000.00 yuan
Maintenance labor costs
Half a year
The operator can also complete
2000.00 yuan
Calculated in this way, if a commercial-based printing company, and is divided into 2 to 3 shifts of 24 small jobs, a single machine is based on 22 sheets per hour, and the number of publications in a year is about 120,000, in a year in CTP machines Under normal operation, the cost of consumables is roughly: 17220.00 yuan.
According to some calculations, some customers will shout. The cost of our CTP is far more than this. If all the maintenance of the user depends on the supplier to operate, you may need to pay a higher fee. But now most suppliers are more willing to choose to sign relevant maintenance contracts to provide services, so as to make time and technology more secure, even so we still need to talk about the following common problems and maintenance content related to CTP. [next]
Second, the common problems of CTP machines
During the use of the CTP machine, due to its compact structure and good design, generally speaking, there are relatively few problems, but long-term movements also inevitably have some problems. The following common problems are listed as follows:
1. The failure of the plate-feeding system. Most CTP plate-feeding systems are operated by pneumatic devices. The pneumatic part includes the machine's protective door, platen rubber roller, platen head clamp, platen tail clamp and other devices. Most customers can complete some of the adjustments themselves, and even some customers can also replace the parts themselves.
2. The faults during the exposure process may be a little more difficult than the mechanical actions, but as long as the analysis is serious, it is not difficult to find the end of the problem. We can analyze it according to the thinking: the fault of the plate itself, Faults in the development process, file problems, problems in the exposure process, and man-made problems, etc., so as to easily find the problem and solve it further.
3. The problem of the circuit and the sensor part. The circuit problem usually includes software guidance and data storage, and the sensor part is the operation detection of all actions and safety protection devices. Most of the error information of the machine can point out the core part of the problem For copies and solutions, customers can troubleshoot by themselves or by contacting relevant technical personnel.
4. The laser part of the problem, most of the laser problem manifested in the output plate, generally can be solved by adjustment, and if the temperature and humidity cause the problem, the customer can also solve it by themselves, if it is really a small part If the internal circuit of the laser is faulty, it needs to be replaced.
5. The failure of the next edition is the same as that of the previous edition. The lower edition is divided into automatic and manual. Most of them are also mechanical actions and some position sensing. As long as there is more maintenance, there will be no major failure.
The general location of the common problems listed above is also to remind customers that a stable CTP system requires careful maintenance. And good maintenance includes:
3. Content of CTP maintenance
Through daily and planned cleaning, lubrication and proper adjustments to the maintenance of equipment, the maintenance cost of equipment can be minimized. The maintenance of CTP equipment is mainly reflected in the following aspects:
1. Observe the safe operation and strictly follow the physical and chemical safe operation of the equipment to eliminate unsafe factors.
2. Appropriate lubrication, good lubrication can effectively improve the operation part, especially the screw and slide of CTP, must be regularly added with qualified oil.
3. Arrange the related connection lines, air intake, drainage and other devices. If all the connecting parts can work normally, they can also ensure the normal operation of the entire system.
4. Clean the inside and outside of the machine. Cleaning is the first of all maintenance contents. Due to the dust of the laser candle burning inside the CTP machine, the attachments moved by each rubber roller will inevitably increase the load of the machine. Therefore, cleaning is particularly important in the use of CTP.
5. Properly adjust the temperature and humidity of the environment. Temperature and humidity are very important for CTP machines. Excessive temperature can easily cause the accelerated aging of the thermal laser head. Excessive humidity is very unfavorable for the cleaning of the plate and the inside of the machine, so CTP It is best to use the machine within the specified temperature and humidity range. In case of abnormal temperature and humidity, it is recommended that you adjust the environment quickly. The temperature of a conventional CTP room is 20 ± 2 ℃ and the humidity is 50% ± 10. A comfortable environment can not only guarantee the machine The normal operation of the product can also stabilize the product quality.
6. Ensure that the input voltage and air pressure are normal. Clean and stable voltage and air pressure are the first conditions for the healthy operation of the machine. Inputting standard voltage to each circuit and switching power supply can ensure the normal operation of the circuit board, and stable air pressure can enable the laser head to Effective dust removal can keep all moving parts in good operation.
Of course, in the process of using CTP, it is more important for each company to formulate related maintenance content to manage according to its own needs.
4. The importance of CTP equipment maintenance
The daily maintenance of equipment is the basic work of equipment maintenance. Its importance is directly reflected in its production value. In the field of long-term maintenance of CTP, most people find that the life of the thermal laser head is 3000-5000 hours, and it is in good condition. In the environment where thermal laser heads have been used for more than 10,000 hours, it is often understood that the environment of these laser heads that exceed tens of thousands of hours is absolutely quite good, plus the good quality of CTP operators , Not only solved the problem in time, but more importantly, reduced maintenance and repair costs, thereby improving efficiency.
Cooperation with suppliers can not only improve the skills of CTP operators, but also understand the performance of equipment in learning, so as to control CTP machines. At present, in terms of CTP market, most of the suppliers can provide good services for customers And a variety of solutions, such as: remote diagnosis provided by Kodak Company, 800 toll-free telephone and network technology support platform, etc., are to provide customers with meticulous service care. Therefore, when there is a problem with the machine, we need to consult more professional personnel in time to deal with it, rather than wasting maintenance time.
On the other hand, many merchants only purchase one CTP device. If the negligence of maintenance leads to a shutdown of the entire flow printing operation, such losses will be even greater. Here, we should remind the managers of CTP that the careful maintenance of CTP equipment is completed and performed by the operator. Only when the operator uses the equipment correctly can the good performance of the equipment be maintained, the efficiency of the equipment be fully utilized and the service life extended, while reducing or Avoid sudden failures and don't rely solely on solutions that come back for repairs if something goes wrong.
When you decide to purchase CTP equipment, pay attention to the equipment to bring you benefits, but also pay attention to the maintenance plan you will pay for the equipment, through daily maintenance and continuous accumulation and summary of lessons learned, cultivate protection awareness, rely on initiative The maintenance method can resist faults and reduce losses to the greatest extent, so that CTP equipment can really play a long-term and high-yield.
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