Country: Indonesia
1.Printed Product
Product Name: Two color pad printing machine with work table + silk screen printer + Infrared Dryer for ink + production line + silk screen manual printer
Product Application: for different healthy products like transparent small buttons, Hand-held plastic massager plastic part , transparent pc panel cover etc
Product Material: PC plastic and different shapes of products , works in a production line
2.Printing Application
For small buttons, they are Operational instruction symbols
For Hand-held plastic massager , the printed content is the brand name -company logo
☑ Logo □ Text ☑ Symbols □ Pattern □ Other:
3.Customer Requirements & Challenges
(1) Previous Printing Method
□ Manual Printing
□ Existing Printing Machine
☑ Outsourced Printing
□ Other:
(2) Main Challenges
- Unable to achieve required printing effect
- High labor cost
- Unstable production lead time
3.Product & Printing Requirements
(1)Product Size
Product 1: transparent plastic pc panle: size 20*20cm , printed logo size:2*0.5cm
Product 2: s set – 5 pcs transparent small buttons: max diameter 18mm , print dimension: 17mm
Proudct 3: plastic part : 13cm*8cm , print dimension: 6*1.5 cm
(2)Printing Area
Diversify printing based on different product
(3)Printing Colors:two colors
(4)Production Requirement
Hourly production: 1500pcs /hour
Client want to purchase a complete production line to meet his diversify printing demand
(5)Special Requirements
- Printer from the back side for the transparent products
- Customized different fixtures to print different product
- One machine can meet different product printing demand.
- Printing quality need to be the same as the one when their outsourced
- Sample printing before delivery
4、ENGYPRINT Solution
（1）Machine Solution
Equipment name: Two-colour closed ink cup machine with work table
Equipment model: EN-C160/2A
Equipment name: Semi-automatic screen printer with flat work table
Equipment model: EN-PS2030V
Equipment name: Manual screen printer for line printing
Equipment model: EN-M100150
Equipment Name: 10-metre production line conveyor with 3-metre infrared drying tunnel
Equipment Model: EN-APM
（2）Customized Solution
- Full electric driven pad printer , compare to the traditional air Pneumatic Pad Printing Machine, it is more accurate, and can save cost for air compressor
- Customized different fixtures to help client print different product without change machine
- Customized etching plate helped client to adjust the logo angel on the film to ensure logo can be printed on the correct location and match with fixture well.
- Customized production line with dry tunnel to make the production can run smoothly
（3）Consumables Provided
☑ Printing Pad ☑ Printing Plate ☑ Ink Cup ☑ Ceramic Ring □ Printing Ink □ Other
（4）Technical Support
- Sample testing
- Machine adjustment
- Operation training
- Engineering suggestion to achieve the best printing solution
5、Project Process
（1） Confirmation of requirements
Client provided the required printing product image for inquiry, according to the demand, we found, some of the products are suitable for pad printing, one of the major logo is better for silk screen printer, as it is a transparent panel, printing logo size is as big as 20cm* 5cm, it is better to have a dryer after silk screen printing to guarantee the printing quality, dry the ink faster can prevent the dot and dust in the logo.
In order to make the whole production process is smooth and improve production capacity, customer and us both believe it is better to make a production line.
（2）Conceptual Design
- After full discussion, we suggested a full electric driven two color pad printer with work table for the small buttons and small logos
- Silk screen printer for big logo
- Infrared dry tunnel assemble in the 10 meter production line
- Engyprint designed the carbon steel plate and silk screen printer plate
- And a small manual silk screen printer for the simple logo on the panel to save cost.
（3）Testing and Validation
- Client has sent his team to our factory for machine operation study and sample printing result confirm before delivery
- According to the sample printing, we gained experience that the etching depth for the bigger round dot cannot be the same as other small logos, it should be less, between 0.02-0.022mm to guarantee good printing result, the hardness for the pad need to be harder to shore A10-12.
- The way to put the buttons on fixture need to follow the correct direction.
- If client want to change the fixture to print from 2 color to one color, the machine can be adjusted to print 2 pcs at a time to improve printing speed.
（4）Handover for use
Machine production lead time 20 days , we have provided operation videos , user manual and related consumables to client.
After client get the machine, Engyprint kept providing continuous support to help client assemble the production line and machines, get familiar with the machine features, and learn how to print well.
For example:
- We taught client to use screen washing agent to clean the silk screen plate after use it for easier clean and better keep.
- When the ink cannot released completely from the silicone pad after printing, we suggested client to use thinner to clean the pad first and add few thinner in the ink , when some pad mold release agent remain on the pad, the printing quality cannot be good.
- When client cannot do the silk screen printing well, after check the pictures , we found the distance between the silk screen plate and the product need to be adjusted, the best distance is 4mm.
- When the pad printed logo is not clear, we suggested client to adjust ink consistency according to our video
- In order to protect the ceramic ring well when assemble the ink cup on the plate, we took a video to tell client to helped them follow the correct process.
6.Project Results
- Improved printing stability
- Increased production efficiency
- Reduced manual operation cost
- Achieved stable mass production
- Solved different products printing demand
