With the gradual upgrading of domestic flexible packaging equipment and technology, the competition in the same industry intensifies. Playing the service card leads to the rise of service cost, and seizing customers and orders leads to the relative decline of profit margin. Affected by the international financial crisis, the order volume of some export packaging enterprises decreased than before. At this time, it is particularly important to do a good job in opening up sources, reducing expenditure and cost control.
Many company owners and managers understand that in order to make money, the cost must be controlled. So they think of many ways to control the cost, such as the control of travel expenses, the switch control of lighting lamps, the control of communication costs, the purchase of tools, the maintenance and transformation of equipment, and even require the use of the back of the paper that has only been used on one side, and even pay attention to and control the amount of toilet paper used in the toilet and the water flow rate of the faucet As long as we can save as much as possible, but how to control the production cost of flexible packaging enterprises?
1、 Printing process
In the printing process, the larger loss point appears in the adjustment loss of color matching and overprint. For example, the general domestic machine in the printing of 8 colors of products, the general enterprise will give employees a loss on the machine and color number loss. In general, the best control of power loss is about 150 ~ 300m, which is an ideal value. The loss of color number is to add 50M / color to each color, which can be done by ordinary enterprises. But why do some enterprises still have losses far beyond this number?
The key is human control. For example, using waste materials to color, proofing and other methods, these conventional consumption reduction methods are also the simplest way that ordinary enterprises can do. In the printing process, employees and basic management personnel will think that as long as we control the quality of machine production is a good explanation, or as long as there are no quality problems. Employees rarely care about wastage. If the benefits saved can be shared with employees, that is to say, some rewards for reducing consumption can greatly improve the enthusiasm of employees to reduce consumption and form a win-win situation.
2、 Energy consumption
The loss of raw materials is superficial and directly manifested, so we generally realize that there are some loss points that we pay less attention to or ignore. For example, the energy consumption in our process is not directly shown in the production report, but it is a very large application loss point. For example, the invisible emission of heat energy and the white discharge of solvents outside the production plant are very considerable. We should pay attention to these losses and take corresponding measures to reduce the overall consumption in this respect. For example, the recycling system is used to recover part of the heat energy, so that it can be reused, and the waste heat can be recycled.
In printing, when multi printing units are used to print orders with less color number, such as 10 color machine, only 5 color products can be printed, an exhaust controller can be added to the printing unit to turn off the exhaust air of the oven that is not needed, reduce the power of the main exhaust motor, and save 20% ~ 40% of the electricity bill.
3、 Material loss

There is also a critical scrap loss. At present, most enterprises, especially large enterprises, do not pay much attention to this detail. Generally, if our leftover can be controlled to 15mm or narrower, the loss point can be directly reduced, and the profit margin in this process can be 1% ~ 3%. This control can be realized by people, but most enterprises think that the operating habits of employees are difficult to change. This is a management misunderstanding and a production "black box" which is easy to ignore, which is worthy of our attention.

4、 Compound process
What are the loss points in the composite process?
Many enterprises are looking at glue. At present, a large number of enterprises put their hope on solvent-free glue, water glue and so on, hoping to reduce production costs. In fact, whether using two-component polyurethane adhesive, solvent-free glue or water glue, we often enter such a misunderstanding: only concerned about the price, and less to pay attention to the amount of glue. At present, more and more foreign enterprises have applied ceramic wire roller. The biggest characteristic of ceramic wire roller is that the amount of glue is less, but the glue surface can be smoother than the steel roller used in China. The composite interlaminar strength can also meet the corresponding requirements, and the glue amount can be reduced by about 20% ~ 30%. This figure is a big ratio for the cost of composite process For example. If we can control the amount of glue, then our material consumption rate in production will be greatly reduced. Its disadvantage is that it can only be applied to light packaging products.
Another big consumption reducing link is the heating mode of compound oven. At present, electric heating or coal burning are widely used in many enterprises, and the cost is naturally relatively high. However, some enterprises adopt water heating mode, which is worth learning from. Generally, the required temperature of the compound machine oven is 40 ~ 80 ℃. The air flow is heated by the hydrothermal method, and the power consumption can be greatly reduced by combining the solar energy and black diesel or natural gas heating. Moreover, the waste heat of water can be recovered by 50% ~ 80%. In a cycle, the water will always be in the state of its own heat energy, and the water can be adjusted flexibly by the required temperature of the machine The heat source heating loss, and this method is more environmentally friendly and energy-saving, thermal energy recycling, utilization rate is also high. At the same time, when water heating cycle, we can use solar heating mode to store heat energy in water. The circulating hot water heated by solar energy can save a lot of costs for enterprises, especially suitable for soft package enterprises in southern region.
5、 Bag making process
In the bag making process, there are two obvious loss points: one is the direct scrap scrap loss. In this aspect, we should make relevant budget before the business order is placed, and determine the scrap loss rate; on the other hand, it is also a large loss point and an important part of manpower consumption.
We can adjust the machine through the adjustment products of the previous process or other waste materials, without using good products for debugging waste, which is for general general purpose products. Then for the more special products, we need to consider another problem: the process of mechanization.
At present, for soft bag enterprises, straw bags, pressure valve bags, special-shaped bags, etc. have more complex operations in the production process. At present, the straw bag is rarely fully mechanized operation, the pressure straw is manually one by one, the efficiency is very low, and compared with the mechanical production, the quality stability is not so good. The same is true for pressure valve bags. For the special-shaped bag, many enterprises will use the stamping machine to do, which is a routine and relatively easy to operate. But this link can introduce die cutting, which many enterprises do not apply. For example, many imported machines will increase the application of Thomson die-cutting method in the bag making machine position, and directly cut and shape the special-shaped bag. With this method, one process will be saved and the finished product can be directly formed, without the need for stamping process after cutting the regular bag. In this way, it has more advantages in both production efficiency and production quality. Therefore, for special bags, it is necessary to carry out mechanical operation. It can improve the production efficiency, reduce the production cost and obtain the profit growth point.
On the other hand, our management control in the production process. At present, many enterprises are off-line shift, but many large enterprises have realized non-stop shift, which can avoid the production loss of shutdown and start-up. This is also worth learning.
Although flexible packaging has been in the era of meager profits, most enterprises do not have much working capital to invest in purchasing new equipment and new materials, but we can transform and improve our production process from different angles and production modes, adopt different production process management modes, and explore and discard the "hidden waste" in production, even small enterprises can improve Our production profit, enhance the competitiveness of enterprises.
Dongguan Beite packaging materials Co., Ltd. - located in Dongguan City, the world's manufacturing city, is a subsidiary of Beite packaging (China) Co., Ltd., with a plant area of 6000 square meters. It is a flexible packaging enterprise integrating R & D, production and sales. It has a complete set of domestic advanced production equipment, a scientific and humanized management system and a group of experienced technical personnel For backing, to provide customers with quality products and first-class service.
The company produces composite bags, roll film, fruit bags, aluminum foil bags, suction mouth bags, self-supporting bags, zipper bags, anti-static bags, special-shaped bags, etc., which are suitable for the internal and external packaging of food, daily chemicals, electronics, toys, medicine, cosmetics, industrial products and other industries.
We uphold the integrity of cooperation, good quality, good service business philosophy, won the industry's approval, products sold to all over the world; welcome friends from all walks of life to inquire, visit our factory to investigate guidance and business negotiations.