A small batch personalized printing order printing method
By combining plate-making and online inspection technologies with a deep drying device, the problems of low efficiency and high cost in traditional printing production lines for small-batch personalized orders have been solved, achieving high-efficiency, low-cost personalized printing quality production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- TAIZHOU FOREST COLOR PRINTING PACKING
- Filing Date
- 2026-03-31
- Publication Date
- 2026-06-16
AI Technical Summary
Traditional printing production lines suffer from problems such as frequent plate changes leading to low production efficiency, low substrate utilization, and high cost per unit when handling small-batch personalized orders, making it difficult to meet the requirements of fast delivery and economy.
By employing imposition processing and parameter preset technology, multiple personalized orders can be efficiently integrated, and printing and drying parameters can be dynamically adjusted during the production process. At the same time, online detection and deep drying devices are introduced to ensure printing quality.
It enables efficient production of small-batch orders, improves production efficiency, reduces costs, ensures the high quality of every printed product, and meets the requirements of personalized customization.
Smart Images
Figure CN122211091A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of printing technology, and specifically refers to a method for printing small-batch personalized printing orders. Background Technology
[0002] With the development of the market economy and the diversification of consumer demands, the market demand for personalized and customized printed materials is growing daily. Small-batch, multi-variety, and rapid delivery have become important development trends in the printing industry, especially in commercial and packaging printing. However, traditional printing production lines, such as offset printing lines, are mainly designed for large-volume, long-run printing tasks. Their production mode usually requires the production of fixed printing plates, and preparation processes such as plate changing and ink mixing are complex and time-consuming. When faced with a large number of small-batch, personalized orders, traditional production lines will face the following prominent problems: First, frequent plate changes lead to low production efficiency and increased costs. Each order change requires downtime to replace the printing plate and adjust printing parameters, which not only consumes a significant amount of effective production time but also increases material waste and labor costs, making it difficult to meet the short delivery time requirements of personalized orders.
[0003] Secondly, the low utilization rate of printing substrates leads to resource waste. In order to meet the minimum printing size of traditional printing presses, small-batch orders often require printing only a small amount of content on a single printing substrate, resulting in most of the substrate area not being effectively utilized, creating a large amount of scrap material. This waste is particularly significant for high-priced specialty papers or films.
[0004] Finally, the high cost per printed item makes it uneconomical. In the cost structure of traditional printing, prepress plate-making fees and machine setup fees account for the main part of fixed costs. When order batches shrink to a few hundred or even a few dozen copies, the high fixed costs are spread across each printed item, causing the unit price of small-batch orders to remain high, and even making them uncompetitive in the market. Summary of the Invention
[0005] The purpose of this invention is to provide a method for printing small-batch personalized orders that can efficiently and flexibly handle such orders while also ensuring high substrate utilization.
[0006] This invention is implemented as follows: A method for printing small-batch personalized printing orders includes the following steps: Step S1: Imposition processing, where operators use an imposition device to imposition the graphic information to be printed to generate an imposition file; Step S2: Instruction issuance and parameter preset: The imposition file and the printing control parameters corresponding to the current printing job are sent to the printing device; Step S3: Unwinding and feeding: The unwinding device supplies the substrate roll, and multiple drive rollers guide the substrate along a preset path through each subsequent station. Step S4: Preheating and drying before printing. Before the substrate enters the printing station, the substrate is preheated and dried using a heater integrated inside at least one drive roller. Step S5: Printing, the printed graphic information after imposition is printed onto the substrate using a printing device; Step S6: Synchronous drying. While the printing device is printing, a synchronous drying device located in the transmission roller below the printing device is used to simultaneously heat and dry the printed substrate so that the ink layer can be quickly set. Step S7: Deep drying, the printed substrate is conveyed to the deep drying device for drying; Step S8: Rewinding. The processed substrate is rewound into a roll using a rewinding device.
[0007] In the above-described method for printing small-batch personalized printing orders, step S7 further includes: Step S7-1: Vertical drying. The printed substrate is conveyed to the vertical drying device, where it is conveyed vertically and dried. Step S7-2: Deep curing and drying. The substrate that has been dried vertically is transported to the deep curing and drying device for secondary deep heating and curing.
[0008] In the above-described method for printing small-batch personalized printing orders, an online detection step S9 is also provided between step S7 and step S8: S9-1, the dried substrate is transported into the box of the online detection device, and the substrate is guided and transported through the box at a uniform speed in the horizontal direction by multiple transmission rollers set in the box; S9-2, the image acquisition device mounted on the sliding bracket is driven by the drive mechanism to move back and forth along the width direction of the substrate, and scans and takes pictures of the surface of the substrate passing through the box in real time, so as to collect image information of the entire area of the substrate. S9-3, The image information acquired by the image acquisition device is transmitted to the control system, which compares the received image information with a preset standard to determine whether the printed matter is qualified. If the comparison result is qualified, the printed material is controlled to continue to the winding step; If the comparison result is unqualified, the control system will automatically record the location and type of the defect and issue an alarm to remind the operator.
[0009] In the above-mentioned method for printing small-batch personalized printing orders, step S10 is also included: cutting. After step S8, the rolled-up substrate is cut to a fixed length according to the preset order size by a cutting device to form independent small-batch printed products.
[0010] In the above-mentioned method for printing small-batch personalized printing orders, the specific steps of the imposition process in step S1 include: Step S1-1: Data acquisition, acquiring the graphic data to be printed from the operating terminal; Step S1-2: Imposition processing. The image and text data are impositioned using the imposition processing module to generate an imposition file.
[0011] In the above-mentioned method for printing small-batch personalized printing orders, the specific steps of step S2, namely issuing instructions and setting parameters, include: Step S2-1: Data reception and parameter configuration. The control host receives the imposition file through its data interface, and the parameter configuration unit sets the printing control parameters corresponding to the current printing job according to the imposition file. Step S2-2: Instruction issuance. The instruction sending unit of the control host sends the image and text data after imposition and the corresponding printing control parameters to the printing device to control it to perform the printing operation.
[0012] The outstanding advantages of this invention compared to the prior art are: 1. This invention efficiently integrates the graphic and textual information of multiple personalized orders through imposition processing and parameter preset, and dynamically pre-adjusts the printing and drying parameters of the next order during the production process, achieving "seamless connection" between orders with different patterns and specifications. It completely eliminates the waiting time caused by frequent plate changes and machine adjustments in traditional printing, enabling small batch orders to achieve a turnover efficiency comparable to large-scale production, while reducing printing costs.
[0013] 2. This invention uses an online full-frame inspection device to scan and locate defects in each personalized printed product in real time, preventing batch quality accidents and ensuring that every delivered printed product meets the high-quality requirements of personalized customization. Attached Figure Description
[0014] Figure 1 This is a three-dimensional schematic diagram of the printing production line corresponding to the present invention.
[0015] Figure 2 This is a schematic diagram of the unwinding device of the printing production line of the present invention.
[0016] Figure 3 This is a schematic diagram showing the connection between the first linear driver and the adjusting bracket of the unwinding device of the present invention.
[0017] Figure 4 This is a schematic diagram of the image acquisition device of the printing production line of the present invention mounted on a sliding bracket.
[0018] Figure 5 This is a schematic diagram of the heating door of the vertical drying device of the printing production line of the present invention in the open state.
[0019] Figure 6 This is a partial schematic diagram of the heating gate of the printing production line of the present invention.
[0020] Figure 7 This is a schematic diagram of the deep curing and drying device for the printing production line of the present invention.
[0021] Figure 8 This is a partial schematic diagram of the winding device of the printing production line of the present invention.
[0022] In the diagram: 1. Imposition device; 2. Unwinding device; 3. Substrate roll; 4. Vertical drying device; 5. First heating lamp; 6. Deep curing drying device; 7. Rewinding device; 8. Mounting shaft; 9. Adjusting bracket; 10. First linear actuator; 11. First slide rail; 12. Control console; 13. Printing chamber; 14. Fixed frame; 15. Heating door; 16. Second linear actuator; 17. Equipment base; 18. Second slide rail; 19. Reflector; 20. Drying chamber shell; 21. Exhaust channel; 22. Box body; 23. Sliding bracket; 24. Image acquisition device. Detailed Implementation
[0023] The present invention will be further described below with reference to specific embodiments. Example 1: See Figure 1-8 : This embodiment provides a method for printing small-batch personalized printing orders, based on a corresponding printing production line (such as...). Figure 1 (As shown in the image). This method is particularly suitable for handling personalized printing orders with small batches, diverse varieties, and varied patterns, enabling efficient and high-quality continuous printing production. The method mainly includes the following steps: Step S1: Imposition processing. The operator uses imposition device 1 to imposition the text and images to be printed, generating an imposition file suitable for subsequent printing. This is a crucial preliminary step for personalized printing. In this embodiment, the imposition file must be in PDF format.
[0024] Specifically, step S1 can be further refined as follows: Step S1-1: Data acquisition. The imposition device 1 acquires the graphic data to be printed from the operating terminal (such as a local computer, mobile device or cloud server) through its communication interface. This data may include various packaging box patterns, brochures, etc.
[0025] Step S1-2: Imposition processing. The imposition processing module built into the imposition device 1 performs imposition processing on the graphic data according to preset layout rules (such as order size, imposition quantity, bleed setting, etc.), efficiently and compactly arranging the graphic information of multiple small orders on a large printing page to generate an imposition file.
[0026] Step S2: Instruction issuance and parameter preset: The imposition file and the printing control parameters corresponding to the current printing job are sent to the printing device.
[0027] Specifically, step S2 can be further refined as follows: Step S2-1: Data reception and parameter configuration. The control host receives the imposition file through its data interface, and the operator sets the printing parameters, such as printing speed, ink volume control, registration accuracy, etc.
[0028] Step S2-2: Instruction issuance. The instruction sending unit of the control host sends the image and text data after imposition and the corresponding printing control parameters to the printing device through the industrial bus or network to prepare for the execution of the printing operation.
[0029] Step S3: Unwinding and feeding. The unwinding device 2 supplies the substrate roll 3 and uses multiple drive rollers (including drive rollers and driven rollers) to guide the substrate so that it passes through the subsequent preheating station, printing station, drying station, etc. stably and uniformly along the preset path under the set tension control.
[0030] Step S4: Preheating and drying before printing. Before the substrate enters the printing station, a heater integrated inside at least one drive roller preheats and dries the substrate. The purpose of this step is to remove moisture that the substrate may have absorbed during storage and transportation, and to raise its surface temperature to achieve optimal printability. This facilitates rapid ink adhesion and drying, preventing ink diffusion or poor adhesion during printing. The drive roller serves both as a guide and transporter of the substrate and as a preheating device, featuring a compact structure and high preheating efficiency.
[0031] Step S5: Printing. Using a printing device (such as an inkjet printing machine), the graphic information after imposition in step S1 is accurately printed onto the preheated substrate according to the received instructions, forming the desired personalized pattern.
[0032] Step S6: Simultaneous drying. While the printing device is printing, a simultaneous drying device (such as an infrared heating lamp, hot air channel, or heating wire) located within the drive rollers below the printing device is used to immediately and simultaneously heat and dry the substrate after printing. Since the ink has just come into contact with the substrate surface at this time, it is highly susceptible to smudging or fading. Simultaneous heating allows the ink layer to quickly and initially set, effectively ensuring the clarity and quality of the printed material and laying a good foundation for subsequent deep drying.
[0033] Step S7: Deep drying. To ensure that the ink is completely dried and cured, especially for printed materials with thick ink layers or high drying requirements, the substrate that has been dried simultaneously is transported to a special deep drying device for more thorough drying.
[0034] In this embodiment, step S7 further includes two steps: Step S7-1: Vertical drying. The printed substrate is conveyed to the vertical drying device 4. Inside this device, the substrate moves up and down vertically, greatly extending its drying path and residence time within the limited space. This allows it to be fully dried by the first heating lamp 5, initially evaporating most of the solvent or moisture in the ink layer. In this step, the drying temperature of the first heating lamp 5 is approximately 60℃ to 120℃.
[0035] Step S7-2: Deep Curing and Drying. The substrate, after vertical drying, is conveyed to the deep curing and drying device 6. This device can use a second heating lamp to perform secondary deep heating and curing on the substrate, ensuring complete cross-linking or drying of the ink layer, achieving the final adhesion and abrasion resistance, thereby guaranteeing the final quality of the printed matter. In this step, the drying temperature of the second heating lamp is approximately 120℃~180℃.
[0036] Step S8: Rewinding. The thoroughly dried substrate is rewound into a roll by the rewinding device 7 to form a large roll of printed semi-finished product, which is convenient for subsequent cutting or direct shipment.
[0037] It should be noted that, as Figure 1 , Figure 2 As shown, the unwinding device 2 in this embodiment is a dual-station alternating feeding structure, including a base with two parallel mounting shafts 8 symmetrically arranged on the base. Each mounting shaft 8 has two adjusting brackets 9 slidably mounted on it. The outer end of each adjusting bracket 9 extends away from the mounting shaft 8, and each adjusting bracket 9 has a support roller shaft for mounting the substrate roll 3 at its outer end. The distance between the two adjusting brackets 9 is adjusted by their sliding position on the mounting shaft 8 to accommodate substrate rolls 3 of different widths. Each support roller shaft independently supports one substrate roll 3. The two substrate rolls 3 are respectively connected to a drive roller.
[0038] During operation, the substrate roll 3 on one station (e.g., the support roller at the loading station) is unwound and fed normally, while the other station can pre-install the roll required for the next order. When the roll being used is exhausted or the order material needs to be changed, the substrate roll 3 on the other support roller is connected to the drive roller for conveying, realizing rapid roll change and greatly improving the continuous operation capability of the production line.
[0039] Specifically, the adjustable spacing between the two adjusting brackets 9 on the mounting shaft 8 is achieved by having two opposing first linear actuators 10 mounted on each of the mounting shaft 8. These first linear actuators 10 drive the two adjusting brackets 9 to move towards or away from each other on the mounting shaft 8. In this embodiment, the first linear actuator 10 is a first hydraulic cylinder, fixed to the mounting shaft 8. The drive rod of the first hydraulic cylinder is connected to the adjusting bracket 9, and the adjusting bracket 9 is slidably connected to the mounting shaft 8 via a first slide rail 11.
[0040] The unwinding device 2 also includes a control console 12, which controls the movement of the first hydraulic cylinder.
[0041] Furthermore, the printing equipment in this embodiment includes a printhead and a gemstone tray, etc. The synchronous drying device is located below the printhead. The drying temperature is 60-80°C. The printing equipment is independently installed in the printing chamber 13, which is temperature-controlled within the range of 20°C-25°C ± 1°C by an air conditioning system to ensure the stability and accuracy of inkjet printing.
[0042] Furthermore, the imposition device 1 of the present invention is a combination of an operating terminal with built-in professional imposition software and a control host. In this embodiment, the hardware of the imposition device 1 is integrated and installed on the housing 22 of the online inspection device (see below for details). Specifically, an industrial control host is installed on the housing 22, which has a built-in imposition processing module and is connected to the operating terminal. The operator inputs graphic data of multiple small-batch orders through the operating terminal. The imposition processing module automatically optimizes the layout according to the printing area of the current printing device and the actual width of the substrate, and generates an imposition file. The data interface is used to receive the imposition file; the control host receives the imposition file through the data interface, sets parameters such as printing speed and ink volume through the parameter configuration unit, and finally sends the impositioned graphic data and control parameters to the printing device through the instruction sending unit to control it to execute the printing operation.
[0043] like Figure 1 , Figure 4 , Figure 5 and Figure 6As shown, in this invention, the vertical drying device 4 includes a fixed frame 14, a heating gate 15, and a second linear actuator 16, which is a second hydraulic cylinder or a pneumatic cylinder. The fixed frame 14 has several transmission rollers spaced vertically to guide the substrate vertically. The heating gate 15 is slidably mounted on the equipment base 17 and is positioned opposite the fixed frame 14. Multiple first drying lamps 5 are spaced vertically on the side of the heating gate 15 facing the transmission rollers. The fixed end of the second linear actuator 16 is connected to the fixed frame 14, and its movable end is connected to the heating gate 15, driving the heating gate 15 to move along a second slide rail 18 to approach or move away from the fixed frame 14. This allows the first drying lamps 5 to dry and heat the substrate driven by the transmission rollers when the device is closed. The second slide rail 18 is fixed to the fixed frame 14 and is positioned along the direction of movement of the heating gate 15.
[0044] In the material feeding or maintenance state, the second linear actuator 16 can drive the heating gate 15 away from the fixed frame 14, forming an open space, which is convenient for operators to feed the printing material belt or clean the equipment. When drying is in normal operation, the second linear actuator 16 drives the heating gate 15 to move towards the fixed frame 14, so that the heating gate 15 is in the closed state. At this time, a narrow drying channel is formed between the multiple first drying lamps 5 on the heating gate 15 and the drive rollers on the fixed frame 14. The contact edges of the two are provided with high-temperature resistant sealing strips (such as silicone rubber strips), which can perform close-range and high-efficiency drying and heating of the printing material that reciprocates on the drive rollers.
[0045] It should be noted that the vertical drying device 4 is also equipped with an exhaust fan and an exhaust channel.
[0046] Furthermore, a plurality of reflective blocks 19 are arranged vertically at intervals on the heating gate body 15, and the first drying lamp tube 5 is installed between adjacent reflective blocks 19. The cross-section of the reflective block 19 is triangular, with its inclined surface facing the direction in which the substrate travels. This triangular reflective block 19 structure design can effectively focus and directionally reflect the light scattered in all directions by the first drying lamp tube 5, so that it radiates more concentratedly onto the surface of the substrate that reciprocates on the transmission roller, thereby significantly improving the photothermal utilization efficiency.
[0047] like Figure 1 , Figure 7As shown, to save space, the production line of the present invention places the deep curing drying device 6 above the vertical drying device 4 and the printing chamber 13 to utilize vertical space. Specifically, the deep curing drying device 4 includes a drying chamber shell 20, with drive rollers densely arranged inside the drying chamber shell 20 along the substrate transport path, and a second drying lamp tube installed inside the drying chamber shell 20 to dry the substrate transported on the drive rollers.
[0048] Similarly, the deep curing drying device 4 is also equipped with an exhaust fan and an exhaust channel 21 to discharge the evaporated solvent or water vapor.
[0049] Example 2: See Figure 1 , Figure 4 : This embodiment is an improvement on embodiment 1. The main difference is that an online detection step S9 is set between step S7 and step S8 to ensure the yield rate of printed materials.
[0050] Specifically, step S9 includes: S9-1, the substrate that has been dried in the deep drying step S7 is continued to be conveyed by the drive rollers. These drive rollers are installed inside the housing 22 and smoothly guide and convey the substrate at a constant speed in the vertical direction within the housing 22 and through the housing 22, creating a undisturbed and stable environment for image acquisition.
[0051] S9-2, a sliding bracket 23 is provided in the housing 22 along a direction parallel to the axis of the transmission roller. An image acquisition device 24 (such as a CCD or CMOS industrial camera) mounted on the sliding bracket 23 is driven by a drive mechanism (such as a servo motor and a lead screw) to move at high speed along a horizontal track perpendicular to the direction of substrate transport, i.e., the width direction of the substrate. During the movement, the image acquisition device 24 performs real-time and continuous scanning and photography of the surface of the substrate passing through the housing 22, thereby acquiring complete image information of the entire surface of the substrate.
[0052] S9-3 transmits the image information acquired by the image acquisition unit 24 to the control system in real time. The image processing and analysis software built into the control system performs high-speed comparison of the received image information with preset standard images or quality standards (such as color deviation, registration accuracy, presence of smudges, ink splatter, ink breaks, etc.) to determine whether the current printed product is qualified. If the comparison result is qualified, the control system will control the production line to continue running, and the printed material will continue to enter the rewinding step.
[0053] If the comparison result is unqualified, the control system will automatically record the specific location of the defect on the roll material (e.g., based on the length coordinates fed back by the encoder), the defect type (e.g., color difference, dirt spots, missing print, etc.), and immediately issue an audible and visual alarm to alert the operator. The operator can then adjust the process parameters in a timely manner based on the recorded information.
[0054] Example 3: Based on Example 1 or Example 2, this embodiment also includes a step S10: cutting, according to the final delivery requirements of small-batch personalized orders.
[0055] After step S8, the wound substrate roll is transferred to the cutting device, or the cutting device is integrated at the end of the production line. The cutting device cuts or die-cuts the continuous roll according to the preset size requirements of the initial order, thereby dividing and processing the large roll of semi-finished product into individual, ready-to-deliver small batches of printed finished products, such as business cards, invitations, flyers, personalized labels, and packaging boxes.
[0056] In summary, the small-batch personalized printing order method provided by this invention, through refined process design, particularly the tiered preheating, simultaneous drying, and deep drying strategies, as well as optimization of imposition, inspection, and cutting processes, forms a complete, efficient, and high-quality personalized printing production solution. This method effectively addresses the challenges of frequent small-batch order changes and diverse pattern variations, significantly improving production efficiency and automation levels while ensuring print quality.
[0057] The above embodiments are merely one of the preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent changes made in accordance with the shape, structure and principle of the present invention should be covered within the protection scope of the present invention.
Claims
1. A method for printing small-batch personalized printing orders, characterized in that: Includes the following steps: Step S1: Imposition processing, whereby the operator uses the imposition device (1) to imposition the graphic information to be printed to generate an imposition file; Step S2: Instruction issuance and parameter preset: The imposition file and the printing control parameters corresponding to the current printing job are sent to the printing device; Step S3: Unwinding and feeding: The substrate roll (3) is supplied through the unwinding device (2), and multiple drive rollers are used to guide the substrate along the preset path through each subsequent station in sequence; Step S4: Preheating and drying before printing. Before the substrate enters the printing station, the substrate is preheated and dried using a heater integrated inside at least one drive roller. Step S5: Printing, the printed graphic information after imposition is printed onto the substrate using a printing device; Step S6: Synchronous drying. While the printing device is printing, a synchronous drying device located in the transmission roller below the printing device is used to simultaneously heat and dry the printed substrate so that the ink layer can be quickly set. Step S7: Deep drying, the printed substrate is conveyed to the drying device for drying; Step S8: Rewinding, the processed substrate is rewound into a roll by the rewinding device (7).
2. The method for printing small-batch personalized printing orders according to claim 1, characterized in that: Step S7 further includes: Step S7-1: Vertical drying, the printed substrate is conveyed to the vertical drying device (4) so that it is conveyed vertically and subjected to drying treatment; Step S7-2: Deep curing and drying. The substrate that has been dried vertically is transported to the deep curing and drying device (6) for secondary deep heating and curing.
3. The method for printing small-batch personalized printing orders according to claim 1, characterized in that: Between steps S7 and S8, an online detection step S9 is also provided: S9-1, the dried substrate is transported to the box (22) of the online detection device, and the substrate is guided and transported through the box (22) at a uniform speed in the horizontal direction by multiple transmission rollers installed in the box (22). S9-2, the image acquisition device (24) installed on the sliding bracket (23) is driven by the driving mechanism to move back and forth along the width direction of the substrate, and to scan and photograph the surface of the substrate passing through the box v in real time, so as to collect image information of the entire area of the substrate. S9-3, The image information acquired by the image acquisition device (24) is transmitted to the control system, which compares the received image information with a preset standard to determine whether the printed matter is qualified. If the comparison result is qualified, the printed material is controlled to continue to the winding step; If the comparison result is unqualified, the control system will automatically record the location and type of the defect and issue an alarm to remind the operator.
4. A method for printing small-batch personalized printing orders according to claim 1, 2, or 3, characterized in that: It also includes step S10: cutting. After step S8, the rolled substrate (3) is cut to a fixed length according to the preset order size by a cutting device to form independent small batch printed products.
5. The method for printing small-batch personalized printing orders according to claim 1, characterized in that: The specific steps of the layout processing in step S1 include: Step S1-1: Data acquisition, acquiring the graphic data to be printed from the operating terminal; Step S1-2: Imposition processing. The image and text data are impositioned using the imposition processing module to generate an imposition file.
6. The method for printing small-batch personalized printing orders according to claim 1, characterized in that: The specific steps of step S2, which involves issuing commands and setting parameters, include: Step S2-1: Data reception and parameter configuration. The control host receives the imposition file through its data interface, and the parameter configuration unit sets the printing control parameters corresponding to the current printing job according to the imposition file. Step S2-2: Instruction issuance. The instruction sending unit of the control host sends the image and text data after imposition and the corresponding printing control parameters to the printing device to control it to perform the printing operation.