| CPP的小檔案 1.英文：Casted PolyPropylene的簡稱 2.中文：流延聚丙烯 3. CPP薄膜的優點：透明性好、光澤度高、挺度好、阻濕性好、耐熱性優良、易於熱封合 4.應用： CPP薄膜經過印刷、製袋，適用於：服裝、針織品和花卉包裝袋；文件和相冊薄膜；食品包裝；及適用於阻隔包裝和裝飾的金屬化薄膜。 潛在用途還包括：食品外包裝，糖果外包裝(扭結膜)，藥品包裝(輸液袋)，在相冊、文件夾和文件等領域代替PVC，合成紙，不乾膠帶，名片夾，圓環文件夾以及立體袋複合材料。 5.CPP薄膜的性能： (1)厚度20-30um (2)霧度5.5%~6% 霧度是指透明或半透明材料的內部或表面由於光漫射造成的雲霧狀或混濁的外觀，以漫射的光通量與透過材料的光通量之比的百分率表示。 (3)拉伸強度，縱/橫≧40/20Mpa 拉伸強度是指材料受拉伸荷重的極限強度，是拉伸測試中材料產生的最大應力。 (4)表面張力≧42×10-3N/m 表面張力是一種物理效應，它使得液體的表面總是試圖獲得最小的、光滑的面積，就好像它是一層彈性的薄膜一樣；其原因是液體的表面總是試圖達到能量最低的狀態；廣義地所有兩種不同物態的物質之間界面上的張力被稱為表面張力；表面張力的符號是σ或γ，單位是牛頓/米。 (5)軟化點：由於PP軟化點大約為140℃，PP類薄膜可應用於熱灌裝、蒸煮袋、無菌包裝等領域；其與食品接觸性安全，不會影響內裝食品的風味，並可選擇不同品級的樹脂以獲得所需的特性。 二、Cast技術所有的熱塑性塑料薄膜的性能，不僅與使用的塑料原材料粒子有密切的關係，還與薄膜的生產技術及技術參數有關；同一種塑料製品，例如：薄膜可以用不同的生產技術流程來生產，即使用同一種材料同一種生產技術，由於生產時的溫度、壓力、吹脹比等技術參數的不同，所得薄膜的性能也有所差別。 流延(Cast)法生產的薄膜稱流延膜，用C作字頭，如：流延聚丙烯薄膜，稱CPP膜。 流延法薄膜有擠出流延膜和溶劑流延膜兩種。 1、 溶劑流延法溶劑流延法生產的薄膜具有更薄且厚度均勻性更好的優點，1~3um的超薄膜只在某些高科技材料中使用，一般在包裝材料中不採用，因為設備投資大，溶劑毒性大，而且需使用大量溶劑，溶劑回收設備及操作費用較大，只有像玻璃紙等極少數不能或很難用擠出法生產的薄膜才使用溶劑法生產。 此外，聚四氟乙烯(鐵氟龍)和PC(聚碳酸酯)也常用溶劑流延法生產薄膜。 2、T型模頭法擠出機先將原料樹脂熔化，熔融樹脂經機頭流延到表面光潔的冷卻輥上迅速冷卻成薄膜。 經厚度測量、牽引、電暈處理、展平後，切去邊緣較厚的邊料，再次展開並收捲為薄膜捲。 三、CPP流延膜生產技術的要點： 對薄膜性能影響最大的是溫度。 樹脂溫度升高，膜的縱向(MD)拉伸強度增大，透明度增高，霧度逐漸下降，但膜的橫向( TD)拉伸強度下降。 比較適宜的溫度為230～250℃。 流延薄膜比較柔軟，收捲時必須根據膜的厚度、生產速度等因素調整好壓力和張力。 |
| 否則會產生波紋影響平整性。 張力選擇要根據產品的拉伸強度大小而定，通常收捲張力越大，捲取後的產品不易出現捲筒鬆弛和跑偏現象，但在開始捲取時易出現波紋，影響捲平整。 反之，捲取張力小，開始效果好，但越捲越易出現膜鬆弛、跑偏現象。 因此，張力大小應適中，並控製張力恒定。 三、多層共擠流延膜的技術特點： 為了提高薄膜性能，降低成本，滿足用戶多種用途和高性能要求，多層複合膜發展很快，尤其在生活水平相對高、重視環境保護、要求延長食品保質期和質量的發達國家。 多層共聚流延膜也是其中的一種多層膜，改變了CPP薄膜產品性能單一的問題。 1、通用型： 多層共聚流延膜可根據不同用途、設計不同的如用於自動包裝機上的衣料(特別是內衣、褲)包裝、水果包裝等，或用於與印刷後BOPP膜複合成BOPP/CPP二層膜，用於衣料、乾燥食品(如泡麵袋、碗蓋等)包裝。 2、金屬化型： 要求產品表面對蒸鍍金屬(如鋁)具有極強的附著強度，蒸鍍後仍能保持較好的尺寸穩定性和剛性，另一表面具有較低的熱封溫度和較高的熱封強度。 3、蒸煮型： 用於蒸煮的二層共聚CPP，能承受120℃和15MPa壓力的蒸煮殺菌。 既保持了內部食品的形狀、風味，且薄膜不會開裂、剝離或粘結，並具有優良的尺寸穩定性，常與尼龍薄膜或聚酯薄膜複合，包裝含湯汁類食品以及肉丸、餃子等食品或食前加工冷凍食品。 4、高溫蒸煮型： 包裝燒雞、燒排骨和果醬、飲料需121～135℃高溫殺菌的三層共聚CPP膜，其中共聚PP要求比一般蒸煮型用共聚PP性能更好。除三層膜外，還有流延阻隔性五層包裝。 |
2010年5月21日 星期五
[Packaging Material] CPP
[Packaging Material] OPP
| OPP的小檔案 OPP 是Oriented polypropylene縮寫 中文：共擠壓定向聚丙烯薄膜 用途：OPP是專門為裹包包裝而設計的承印材料，適用於需要低收縮性，接近圓柱狀的容器。 比重：0.90 特性：成本比PET更低，也更加耐熱，包裝食物的話，溫度可達95度 優勢：價錢具有競爭力，且產量多，成功阻擋了其它承印材料的進入。 缺點：在白色OPP表面上印刷，需要加入其它的材料來阻止磨擦。 二、OPP、BOPP、CPP的區分 OPP薄膜是聚丙烯薄膜中的一種，由於生產過程為多層擠出，故稱為共擠壓定向聚丙烯薄膜（Oriented Polypropylene Film）。 如果加工中有雙向拉伸的過程，則稱為雙向拉伸定向聚丙烯薄膜（Biaxially Oriented Polypropylene Film），即BOPP。 相對於共擠壓加工過程，另一種稱為流延聚丙烯薄膜（Casting Polypropylene Film，即CPP），相對較厚。 三、OPP薄膜在日用化工包裝中的應用技術介紹 OPP薄膜目前在包裝中的應用，包括不乾膠標籤、模內標籤、卷繞標籤和濕膠點貼標籤，後者在國外主要應用在飲料和酒類貼標，膠質不乾膠標籤、模內標籤應用的領域包括食品、化工、日用化工產品等。 此外，OPP與PE、PVC薄膜一樣均應用於收縮薄膜，優點是透明度高、光澤度好，收縮率及收縮應力大，但熱封性能及熱封強度較差，收縮溫度高，範圍較窄。 對市場相對飽和及同質化的日用化工產品而言，外表就是一切，第一眼的印象決定了消費者的購買行為。 洗髮乳、沐浴乳、清潔劑等產品的使用場合是溫暖潮濕的浴室和廚房，要求標籤防潮且不易脫落，其耐擠壓性必須與瓶體相配，同時透明瓶體對於膠粘劑和標籤面材的透明度提出了苛刻的要求。 OPP標籤相對於紙質標籤，具有透明、強度高、防潮、不易脫落等優點，雖然成本有所提高，但可以得到很好的標籤展示和使用效果。 由於標籤本身材料為PP，能很好地與PP/PE容器表面相結合，實驗證明OPP薄膜是目前模內標籤的最好材料，在歐洲食品及日用化工領域得到了大量應用，並逐漸傳至國內，有越來越多的用戶開始關注或採用模內貼標技術。 薄膜上表面一般為光面或珠光面，適合印刷、塗層、鍍金屬、複合等後續工序；中間層提供色度、挺度及結構功能；下表面為共擠注塑層，在注塑後與注塑材料結合為一體，於是整張標籤複合在容器的表面。 四、OPP薄膜在日用化工產品包裝的兩個市場應用趨勢 全球標籤用量以每年3-6%的速度增長，其中占主導地位的仍然是不乾膠標籤。 2003年，啤酒企業開始在高級包裝上採用無標籤效果的「水晶標籤」後，更多的品牌，包括化妝品企業開始關注並採用BOPP/PE不乾膠標籤，進一步推動了不乾膠標籤的市場發展。 透明、亞光或鍍鋁薄膜不乾膠標籤，配合燙金、鐳射壓紋、絲柔印等多種印刷技術，能創造出高檔和富有衝擊力的的視覺效果，開始逐步替代相對比較容易受潮、脫落的紙質不乾膠標籤，主要使用於洗滌類、洗護髮、沐浴類及高檔化妝品類日用化工產品，成為不乾膠標籤的高級應用和新趨勢。 國內另一個市場趨勢是模內標籤，大量應用於食品（冰淇淋）、化工（潤滑油）、日用化工產品（洗髮乳、沐浴乳、清潔劑等）領域。 |
| 模內標籤技術和市場在歐美已相當成熟，由於需要耐高溫並能與PE或PP材質的容器良好熔合，模內標籤採用的材料是OPP薄膜，目前以進口材料居多。 模內標籤在傳達產品信息（圖象可達到高質量的照片效果且不會出現顏色脫離現象），保護產品衛生潔凈度以及提高產品防偽性方面，相比傳統的標籤產品都有著很大的優勢。 當然，由於成本和技術因素，模內標籤的大規模應用還有待國內消費意識的發展，以及終端用戶和供應商的共同推廣和合作，但模內貼標這種先進的貼標形式無疑是標籤市場發展的一個方向。 五、世界共擠壓定向聚丙烯薄膜需求 共擠壓定向聚丙烯薄膜可用作標籤和各種消費品，如糖果、果汁的包裝材料，可滿足各種不同要求，印刷性能、機械加工性能以及防潮避光性能均十分優異，還可層壓到其他材料，如紙張、鋁箔、PE或其它聚合物薄膜上。 西歐共擠壓定向聚丙烯薄膜市場下滑，從數量上看不大可能上升，經濟增長緩慢，軟包裝材料消費量下降，糖果商對共擠壓定向聚丙烯薄膜需求量減少，以及總體下降趨勢，使共擠壓定向聚丙烯薄膜生產商遭受到重大的打擊。 共擠壓定向聚丙烯薄膜工業加強合理化改組，歐洲公司有可能收購或參股亞洲公司。 共擠壓定向聚丙烯薄膜不太可能面臨被其他產品替代的危險，反而可能替代紙張、噴鍍金屬薄膜及鋁箔等用途，從而使消費量增長。 |
[Packaging Material] IPP
| IPP的小檔案 中文：吹脹聚丙烯 英文：Inflation PolyPropylene 用途：一般食品及成衣包装 特性：開口性佳、滑性佳、透明性佳 用於吹膜的PP為IPP技術（上吹和下吹）主要是下吹法，但下吹後薄膜不能馬上用紙芯收捲，因為PP膜有收縮性，24小時後才能用紙捲收，有旋轉牽引設備的可以直接收捲。 吹脹膜（inflation film）可以用英文I表示，吹脹法生產的聚丙烯薄膜，稱為IPP膜。 2、 吹脹法生產薄膜的特點 （1）吹脹膜與流延膜相比較有較高的機械強度，橫向的吹脹和牽引輥的快速牽引，是對塑料薄膜的一種雙向拉伸，因而力學性能比較大。 （2）吹脹膜可以作熱封材料，事實上大多數熱封用膜是使用的吹脹膜，但是其熱封性不如流延膜。 （3）吹脹法生產的速度比流延法要低，薄膜厚度的均勻性不如流延膜好。 3、吹脹膜生產中的注意點 （1）安定筒 安定筒是日本PLACO公司發明的，它是用毛氈包紮在一個不鏽鋼管上的倒圓錐形狀的零件。 使用安定筒的吹脹膜厚度的均勻性好。 （2）露點熔體塑料從液體進入固體的熔點線，露點的高低對吹脹膜的性能有較大的影響： 如果露點高，則吹脹是在液體狀態下完成的，生產出來的吹脹膜性能接近於流延膜。 相反，露點線低，在膜泡下面未吹脹處，也就是說，膜泡的吹脹是在固體高彈態下進行的，生產出來的吹脹膜性能更接近於定向膜，熱封性能變差。 （3）吹脹比 吹脹比是指吹脹後膜泡的直徑與未吹脹的管環直徑之間的比值。 吹脹比與薄膜的橫向性能有關。 吹脹比為薄膜的橫向膨脹倍數，實際上是對薄膜進行橫向拉伸，拉伸會對塑料分子產生一定程度的取向作用，吹脹比增大，從而使薄膜的橫向強度提高。 吹脹比愈大，薄膜的透明度和光澤性愈好，機械強度更好，但是吹脹比太大，則膜泡過大(膜泡不穩定)，薄膜過薄，厚度不均勻性增大，薄膜容易出現皺折，通常吹脹比在2~3為佳。 （4）牽引比牽引比是擠出膜牽引速度與從膜口擠出速度之比，它不僅用於平膜，也用於管膜。通過控製牽引比，使膜在牽引方向上略有取向作用。 牽引比的控製是控製擠出膜冷卻後的厚度唯一有效的方法。 |
| 牽引比愈大，薄膜愈薄，縱向機械性能愈好，過高的牽引比與吹脹比一樣是不合適的，一般牽引比在4~6為佳。 牽引比與吹脹比調節合適，所得到的吹脹膜縱橫向性能可望平衡，否則，縱橫向性能是不平衡的，一般縱向性能大於橫向性能。 （5）二次吹脹技術日本開發了一種叫二次吹脹技術，這種技術是把經過吹脹後熄泡後的塑料薄膜，經加熱輥加熱後，再次吹脹，然後冷卻收捲。 二次吹脹技術可以提高薄膜的開口性(滑性)、提高薄膜的機械強度，生產出厚度更小的薄膜。而且薄膜厚度的均勻性可以提高。 |
[Packaging Material] BOPP Plastic Package Bag
| 一、BOPP 英文：Bi-axial Oriented PolyPropylene，簡稱BOPP 中文：雙軸延伸聚丙烯薄膜 應用：廣泛應用於衣服、鞋襪等包裝，以及香煙、書籍的封面包裝 優點：無色、無嗅、無味、無毒，並具有高拉伸強度、衝擊強度、剛性、強韌性和良好的透明性 缺點：容易累積靜電(在高速運轉的生產線上，需安裝靜電去除器)、沒有熱封性 生產： 可以用管膜法或平膜法生產，不同的加工方法得到的BOPP薄膜性能也不一樣。 平膜法生產的BOPP薄膜由於拉伸比大（可達8-10），所以強度比管膜法高，薄膜厚度的均勻性也較好。 Corona： BOPP薄膜表面能低，塗膠或印刷前需進行電暈處理。 BOPP膜經電暈處理後，有良好的印刷適應性，可以套色印刷而得到精美的外觀效果，因而常用作複合薄膜的面層材料。 熱封性：為了獲得可熱封的BOPP薄膜，可以在BOPP薄膜表面電暈處理後，塗布可熱封樹脂膠液，如PVDC乳膠、EVA乳膠等，也可塗布溶劑膠，還可採用擠出塗布或共擠複合的方法生產可熱封BOPP膜。 強度：BOPP薄膜的引發撕裂強度在拉伸後有所提高，但繼發撕裂強度卻很低，因此，BOPP膜兩端面不能留有任何切口，否則BOPP膜在印刷、複合時容易撕斷。 市場：BOPP塗布不乾膠後可生產封箱膠帶，是BOPP用量較大的市場。 複合： 為了得到較好的綜合性能，在使用過程中通常採用多層複合的方法生產。 BOPP可以與多種不同材料複合，以滿足特殊的應用需要。 如BOPP可以與LDPE(CPP)、PE、PT、PO、PVA等複合得到高度阻氣、阻濕、透明、耐高、低溫、耐蒸煮和耐油性能，不同的複合膜可應用於油性食品、珍味食品、乾燥食品、浸漬食品、各種蒸煮熟食、味精、煎餅、年糕等包裝。 二、BOPP袋 英文：BOPP Plastic Package Bag 中文：高張力強度雙向延伸聚丙烯 製造：BOPP是以PP作為原料，但加工製造過程與一般塑膠袋不同！ 一般塑膠膜、袋，不管是PP、PE、PVC等，加工過程是將顆粒狀的塑膠原料經過加熱熔融後，以押出或吹袋方式即可成型。 BOPP的加工過程是PP原料經加熱熔融後，從押出機(T-Die)壓出膜板，再由鑄膜輪冷卻，然後膜板被帶入縱向延伸機中，經預熱延伸4至6倍，降溫後，再進入橫向延伸機中，延伸8至10倍，即可產出薄膜，再經高壓放電Corona處理即捲曲成膜捲半成品。 Corona即是表面電暈處理，以利後續印刷或上膠作業。 其需經過多次繁複的加工程序，後段加工廠再視客戶需求的尺寸，以特殊封口的方式裁切成BOPP袋！ 三、BOPP雙軸延伸聚丙烯薄膜的「雙軸」與「延伸」的物理及化學意義 BOPP是將PP再做二次加工，第一次是用下吹水冷式，第二次是用遠紅外線(IR)加熱式進行縱向及橫向的雙軸延伸，依所需要的收縮率來控制橫方向之吹脹比與縱方向之拉伸比。 雙軸延伸是分階段或同時完成，而其作用有兩個方向：MD（縱向）及TD（橫向），其化學及物理意義為何？ |
| 1.化學意義： 嚴格說來雙軸延伸這個製程並沒有化學變化，材料的部分延伸前後都一樣是PP/EP共押的材料，沒有任何的變化。 一般的塑膠加工可以說都沒有化學變化，投料前的原料叫某某塑膠粒，加工後只會變成某某膜、板、瓶...等。 除非是反應押出才算是有化學變化。 2.物理意義： 因為化學變化的緣故，導致物理特性有所改變，例如：剛性變高、強度增加、延伸性降低、縱向撕裂強度下降...等。 |
2010年5月19日 星期三
降低包裝成本的巧方法
如何既能有效地降低產品成本又能保證產品品質，是每一位產商都關心的問題，特別是想冰箱、空調和洗衣機等家電由於其體積相對其他產品較大，因此包裝的成本一直佔據著十分重要的一塊。一般電器包裝成本占到總成本的5%左右。如果在不影響包裝質量的情況下。可以把包裝成本降低一個百分點的話，無疑提高了產品的品牌競爭力。在這樣一個大前提下，公司當然要考慮如何降低包裝成本，以保持產品在市場上的競爭優勢。產品包裝成本是產品成本中不可低估的一個組成部分，那麼降低包裝成本就成為企業發展策略中舉足輕重的一環，想出一個個降低包裝成本的巧方法。
自產自“包”出成效
為了保證產品包裝的價格和便於控制包裝的成本問題，一些實力雄厚的家電企業會設立自己的紙箱廠，所有的產品包裝由自己的包裝公司來生產配置，做到自產自包，一步到位，以達到合理降低成本的目的。由產品的特殊性如產品貴重、易破損、必須防靜電、防潮濕等決定的。產品包裝對於市場推廣、開拓具有很強的影響力。為保證產品的安全性和影響力，提供高技術含金量的包裝紙箱。
改變員工對於成本控制的看法，將成本的比例與員工的收入掛鉤，使員工能夠主動想辦法降低廢損，控製成本，取得了非常顯著的效果。
適度降低紙板用量
對原本的包裝箱結構進行優化設計，合理採用新型的包裝結構，此舉不僅降低了瓦楞紙板的用量，而且極具環保意義。在原紙價格不斷走高的今天，這個實在不失為一個控製紙箱成本的好方法。同時兼顧包裝的美觀性和可展示性。選用低克重的包裝材料，設計簡單、用材少的包裝結構。最新的包裝結構改進是將瓦楞紙板中用於增強瓦楞強度的茶板紙去掉，將瓦楞的E楞改為B楞，增加了楞高，提高了瓦楞的抗壓抗震的能力，在減少用料的情況下，強度不變，這樣自然達到降低成本的目的。
選用微細瓦楞紙盒
由於微細瓦楞的楞型較小。其對平面壓力和平行壓力的承壓強度比大楞型高，既安全又牢固，又因較輕的重量而減少了運費，降低了成本。
在相同的使用條件下，微細瓦楞包裝由於具有低克重、高強度的性能，可比普通瓦楞紙箱節約20%的包裝材料，同時也符合當前“輕量化”包裝的發展趨勢。明基相關人士在接受采訪時表示，微細瓦楞包裝擁有諸多優勢，將來在數碼產品包裝上會大有可為，因而贏得了明基的青睞。
優化紙箱配紙
芯紙和瓦楞紙的市場價格比紙板的面紙及里紙低的多，適當增加芯紙和瓦楞紙的克重。降低面紙和里紙的克重。使瓦楞紙箱的紙板配紙“面紙輕磅化，芯紙重磅化”，此舉不僅減少了紙板成本。而且大大提高了紙箱的抗壓強度、耐破度等性能指標，減少了紙箱在存儲和運輸過程中變形和破損等因素，進一步加強了紙箱對於整機的保護。減少了各個銷售網點由於更換紙箱而產生的各種費用。
從設計、材料、採購等方面著手，廣泛收集各類資料，深入紙箱生產廠，認真研究紙箱性能與配紙、生產工藝、倉儲等方面的關係，並根據紙箱的實際使用情況逐步採取一系列措施，使其成本構成更加合理。
紙板配紙的要求“面紙輕磅化，芯紙重磅化”，加強芯紙克重，可大大提高紙箱的抗壓強度，減少紙箱在存儲、運輸過程中的變形、破損率，從而進一步加強紙箱對整機的保護，減少各銷售網點由於更換紙箱而產生的各種費用。
巧妙設計箱型結構
對原先的包裝箱進行優化設計，採用新型的包裝結構，此舉不僅降低了瓦楞紙板的用量，而且極具環保意義。降低了原材料用量，節省了包裝材料，還減少了佔地面積，方便了倉儲，並有效保證了紙箱各方面的物理性能，使紙箱的保護性能與降低成本實現了最佳結合。適當降低彩印包裝的比例，產品的印刷已開始由油墨印刷改為水墨印刷，這樣就很容易達到供貨週期短、不良率低、環保等多重收穫。
培養本地供應商，減少運輸費用
在包裝成本中，運輸費用也是非常重要的一部分。簡化採購程序，減少運輸成本，保證供貨及時，TCL集團決定採取當地採購的形式，開發本地供應商。同時，為保證紙箱質量，總部都會定期對各工廠紙箱進行物理性能檢測，每款紙箱的版面均統一由總部認可，以保證紙箱的顏色、內容無誤。
重新配置紙箱顏色種類
在印刷中每增加一種印刷的顏色，紙箱都要過一個墨輥，而每過一個墨輥，紙箱都要承受印刷機的壓力，瓦楞就會有一定程度的變形。這樣，即使提高用紙，增加成本，紙箱性能也不見得會有預期的效果。為此，就必須對紙箱版面進行了設計改善，化繁為簡，風格力求版面簡潔、重點突出，盡量減少疊印、套印，減小了紙箱生產廠的印刷難度，提高了紙箱的生產效率及產品合格率。為降低成本提供了空間。因為在實際生產中，包裝箱每增加一種印刷顏色，就要換一下絲印及顏料，重新上色，再加上顏料本身的成本，使得彩色包裝箱的成本遠遠高於單色包裝箱。
實施包裝箱共用化
一些家電企業產品的型號較多，且每個型號都會開發一個包裝箱，這樣就給公司的管理帶來不便，同時也降低了包裝紙箱供應商的生產效率和積極性。所以有的公司就會用實施包裝箱共用化的方法來解決。
自產自“包”出成效
為了保證產品包裝的價格和便於控制包裝的成本問題，一些實力雄厚的家電企業會設立自己的紙箱廠，所有的產品包裝由自己的包裝公司來生產配置，做到自產自包，一步到位，以達到合理降低成本的目的。由產品的特殊性如產品貴重、易破損、必須防靜電、防潮濕等決定的。產品包裝對於市場推廣、開拓具有很強的影響力。為保證產品的安全性和影響力，提供高技術含金量的包裝紙箱。
改變員工對於成本控制的看法，將成本的比例與員工的收入掛鉤，使員工能夠主動想辦法降低廢損，控製成本，取得了非常顯著的效果。
適度降低紙板用量
對原本的包裝箱結構進行優化設計，合理採用新型的包裝結構，此舉不僅降低了瓦楞紙板的用量，而且極具環保意義。在原紙價格不斷走高的今天，這個實在不失為一個控製紙箱成本的好方法。同時兼顧包裝的美觀性和可展示性。選用低克重的包裝材料，設計簡單、用材少的包裝結構。最新的包裝結構改進是將瓦楞紙板中用於增強瓦楞強度的茶板紙去掉，將瓦楞的E楞改為B楞，增加了楞高，提高了瓦楞的抗壓抗震的能力，在減少用料的情況下，強度不變，這樣自然達到降低成本的目的。
選用微細瓦楞紙盒
由於微細瓦楞的楞型較小。其對平面壓力和平行壓力的承壓強度比大楞型高，既安全又牢固，又因較輕的重量而減少了運費，降低了成本。
在相同的使用條件下，微細瓦楞包裝由於具有低克重、高強度的性能，可比普通瓦楞紙箱節約20%的包裝材料，同時也符合當前“輕量化”包裝的發展趨勢。明基相關人士在接受采訪時表示，微細瓦楞包裝擁有諸多優勢，將來在數碼產品包裝上會大有可為，因而贏得了明基的青睞。
優化紙箱配紙
芯紙和瓦楞紙的市場價格比紙板的面紙及里紙低的多，適當增加芯紙和瓦楞紙的克重。降低面紙和里紙的克重。使瓦楞紙箱的紙板配紙“面紙輕磅化，芯紙重磅化”，此舉不僅減少了紙板成本。而且大大提高了紙箱的抗壓強度、耐破度等性能指標，減少了紙箱在存儲和運輸過程中變形和破損等因素，進一步加強了紙箱對於整機的保護。減少了各個銷售網點由於更換紙箱而產生的各種費用。
從設計、材料、採購等方面著手，廣泛收集各類資料，深入紙箱生產廠，認真研究紙箱性能與配紙、生產工藝、倉儲等方面的關係，並根據紙箱的實際使用情況逐步採取一系列措施，使其成本構成更加合理。
紙板配紙的要求“面紙輕磅化，芯紙重磅化”，加強芯紙克重，可大大提高紙箱的抗壓強度，減少紙箱在存儲、運輸過程中的變形、破損率，從而進一步加強紙箱對整機的保護，減少各銷售網點由於更換紙箱而產生的各種費用。
巧妙設計箱型結構
對原先的包裝箱進行優化設計，採用新型的包裝結構，此舉不僅降低了瓦楞紙板的用量，而且極具環保意義。降低了原材料用量，節省了包裝材料，還減少了佔地面積，方便了倉儲，並有效保證了紙箱各方面的物理性能，使紙箱的保護性能與降低成本實現了最佳結合。適當降低彩印包裝的比例，產品的印刷已開始由油墨印刷改為水墨印刷，這樣就很容易達到供貨週期短、不良率低、環保等多重收穫。
培養本地供應商，減少運輸費用
在包裝成本中，運輸費用也是非常重要的一部分。簡化採購程序，減少運輸成本，保證供貨及時，TCL集團決定採取當地採購的形式，開發本地供應商。同時，為保證紙箱質量，總部都會定期對各工廠紙箱進行物理性能檢測，每款紙箱的版面均統一由總部認可，以保證紙箱的顏色、內容無誤。
重新配置紙箱顏色種類
在印刷中每增加一種印刷的顏色，紙箱都要過一個墨輥，而每過一個墨輥，紙箱都要承受印刷機的壓力，瓦楞就會有一定程度的變形。這樣，即使提高用紙，增加成本，紙箱性能也不見得會有預期的效果。為此，就必須對紙箱版面進行了設計改善，化繁為簡，風格力求版面簡潔、重點突出，盡量減少疊印、套印，減小了紙箱生產廠的印刷難度，提高了紙箱的生產效率及產品合格率。為降低成本提供了空間。因為在實際生產中，包裝箱每增加一種印刷顏色，就要換一下絲印及顏料，重新上色，再加上顏料本身的成本，使得彩色包裝箱的成本遠遠高於單色包裝箱。
實施包裝箱共用化
一些家電企業產品的型號較多，且每個型號都會開發一個包裝箱，這樣就給公司的管理帶來不便，同時也降低了包裝紙箱供應商的生產效率和積極性。所以有的公司就會用實施包裝箱共用化的方法來解決。
2010年5月17日 星期一
Traditional Plastic (PVC) vs. Eco-Friendly Plastics
Traditional Plastic (PVC) vs. Eco-Friendly Plastics
PVC (Poly Vinyl Chloride) - Comes in both rigid and flexible films. It is one of the most popular plastics. Commercial advantages are low material cost, quick forming time, paints & bonds well, and optical clarity.
RPET (Recycled-Poly Ethylene Terephthalate): Post-consumer recycled PET. Less clear and more brittle than PET.
APET (Amorphous-Poly Ethylene Terephthalate): APET has unmatched clarity and good chemical resistance. APET has excellent taste and odor properties. APET will work better than other plastic resins in cold temperature applications. It is 100% recyclable and environmentally safe.
RPETG (recycled polyethylyene terephthlatate glycol): PETG (RPETG), polyvinyl chloride and oriented polystyrene (OPS). RPETG is less clear than PVC. It is considered brittle and tends to stick to the molds during forming. It is also less available than PET and PVC.
PET (Poly Ethylene Terephthalate): PET is made of Carbon, Oxygen and hydrogen. It is not toxic and has no toxic components. If burned, it will emit CO2 and water with some carbon monoxide. It is the material currently used to manufacture soda and water bottles and it is one of the most recycled plastics.
PLA (Poly Lactic Acid): PLA is biodegradable. It has good chemical resistance and low taste and odor properties. PLA has high clarity, is thermoformed under higher heat and pressure. It seals well to itself but not to other substrates.
Source: Europe - Eco-profiles of the European Plastics Industry - http://Lca.plasticseurope.org/main2.htm
- The following chart compares traditional (PVC) plastic with recycled and biodegradable plastics.
- Depending on your product and your needs, one eco-friendly plastic may be better than another.
| Material Type | Supply Status | Clarity | Forming | Impact Resistance | Energy Index | CO2Index | Heat Deflection |
| PVC | Excellent | Very Good | Excellent | Very Good | 100% | 100% | Excellent |
| RPET | Good | Good | Good | Good | >137% | >220% | Good |
| APET | Very Good | Excellent | Very Good | Good | 137% | 220% | Very Good |
| RPETG | Fair | Good | Very Good | Very Good | >137% | >220% | Good |
| PLA | Limited | Very Good | Good | Good | 100% | Unknown | Poor |
RPET (Recycled-Poly Ethylene Terephthalate): Post-consumer recycled PET. Less clear and more brittle than PET.
APET (Amorphous-Poly Ethylene Terephthalate): APET has unmatched clarity and good chemical resistance. APET has excellent taste and odor properties. APET will work better than other plastic resins in cold temperature applications. It is 100% recyclable and environmentally safe.
RPETG (recycled polyethylyene terephthlatate glycol): PETG (RPETG), polyvinyl chloride and oriented polystyrene (OPS). RPETG is less clear than PVC. It is considered brittle and tends to stick to the molds during forming. It is also less available than PET and PVC.
PET (Poly Ethylene Terephthalate): PET is made of Carbon, Oxygen and hydrogen. It is not toxic and has no toxic components. If burned, it will emit CO2 and water with some carbon monoxide. It is the material currently used to manufacture soda and water bottles and it is one of the most recycled plastics.
PLA (Poly Lactic Acid): PLA is biodegradable. It has good chemical resistance and low taste and odor properties. PLA has high clarity, is thermoformed under higher heat and pressure. It seals well to itself but not to other substrates.
Source: Europe - Eco-profiles of the European Plastics Industry - http://Lca.plasticseurope.org/main2.htm
2010年5月7日 星期五
[Interview] Mark Solomon - MEET THE MAN
News_hound on - last edited on by 
Frosty
Mark Solomon is the Principle Designer for the Voodoo business unit, where he is responsible for the industrial design, packaging design, and brand visual language for Voodoo and VoodooDNA product lines. Mark has over 20 international design awards. His latest is an IDEA Silver award for the HP Blackbird 002. He also holds 34 patents and another 48 patents pending. The other day he sat down with us to talk about the design philosophy behind VoodooPC’s new Envy 133 notebook and Omen desktop computers.
The Next Bench News: These days, the world seems to be all curves and soft forms. Yet, both the Envy and the Omen are square blocks and straight lines. Are you just trying to be different?
Mark Solomon: Voodoo is indifferent to trends, and by doing so has become a trendmaker in its space. But the new design language of Voodoo is more than just being different, it goes back to the brand tenets of what Voodoo is and how it fulfills the brand experience.
TNBN: What do you mean by basic design language?
Mark: All of Voodoo’s products share some common visual and experiential traits. Just like people in a family share certain characteristics—a chiseled jaw, a pointed nose—that are passed down from generation to generation.
TNBN: How do these traits manifest themselves in Voodoo’s products?
Mark: Being originally from HP, we had to study Voodoo of the past to ensure the new Voodoo was true to it’s roots. We discovered a couple of basic truths that are core elements that run throughout its products. First, alot of the products were square or geometric in form. So we decided to build on this family trait by updating and refining it. The result is that the Envy and the Omen share a monolithic form. They’re square blocks, with clean, straight lines and totally flat surfaces. Turn the Envy upside-down and it’s completely flat. There are no bump-outs or curves that you see in other notebooks. The same with the Omen. No extraneous shapes. It’s all business. We’ve taken the square block and made it very sexy.
TNBN: What’s the second basic truth you discovered about how Voodoo builds computers?
Mark: They use high quality materials. The new Envy and Omen take this to the next step by using what I call “performance materials.” For the Omen, we chose aircraft-quality aluminum. Not cast, but extruded. Not only is it lighter and stronger than steel or sheet metal, aluminum has really great thermal properties and dissipates heat more efficiently than other metals.
TNBN: What about the Envy, other than its square shape, it seems like an entirely different animal?
Mark: Vastly different, but also the same. It’s also made of a high-performance material: carbon fiber. A different material, but it shares some of aluminum’s characteristics: it’s ultra light and ultra strong. In order to create a notebook that’s just 0.70 inches thick, weighs less than 3.4 pounds and has a removable battery, there was no other way to do it. By using extruded aluminum and carbon fiber on these machines, it enabled us to design in higher performance—whether it’s super high-powered gaming on the Omen, or increased mobility on the Envy.
TNBN: The LCD screens on the Envy and the Omen are covered with a thick slab glass that goes from edge to edge. We’ve never seen this before.
Mark: It’s a subtle little design feature that emphasizes their clean flush lines. Also notice that the Envy and the Omen have LCD screens covered with a thick slab of glass that goes from edge to edge. It’s a subtle little feature, but it adds to their clean, flush lines.
TNBN: Beautiful. It accentuates the square, monolithic form you were talking about.
Mark: It’s very difficult to do and adds to the unmistakable quality of workmanship that goes into these machines. There are also exposed edges on other parts, as well. For instance, on the keyboard deck of the Envy. And on the Omen’s side panels. This effect only works when you’ve got tight engineering. Most manufacturers try to hide their exposed edges because it doesn’t look quite so sexy when you’re using sheet metal. But we wanted to show the quality and thickness of the materials we are using. The exposed edges also come into play in the personalization of the Envy and the Omen. They show the various layers of paint, wood and other materials that are and will be used to customize and personalize these machines.
TNBN: It’s almost like looking at the strata in a rock formation.
Mark: Exactly. Say a user has his Omen for four years and has applied different paints and surfaces to it during that time. He can see the entire history of his machine just by looking at the edges. You can go a little crazy with this, but you get the idea.
TNBN: Both machines also share a certain thin quality. Was this intentional?
Mark: Yes, we worked really hard to get both machines really thin. When you look at the Omen straight on, despite its mass, it’s thin. We didn’t use any trickery to accomplish this. In contrast, the HP Blackbird’s cantilevered design involves a little bit of optical illusion to hide its size. The only thing that might be construed as trickery in the Omen is the “hover” effect when viewing it from the side. But this actually serves an important function in the cooling of the interior components. This is also why we rotated the motherboard.
TNBN: Yes, we’ve been wondering why everything is turned around on the Omen. How did this novel idea come about?
Mark: Simple science… A proven scientific fact is that heat rises. We wanted to rotate the board 90 degrees to take full advantage of that concept. Why force heat through the front and back of the machine using energy-eating fans when you can accomplish the same thing using natural convection. Of course, we still have placed fans and liquid cooling in the Omen, but we are assisting the cooling process and, in theory, will have a quieter machine.
TNBN: Does anyone else do this on their machines?
Mark: Convection techniques have been employed, but, as far as I know, no one has rotated the motherboard on a large desktop. Another functional reason we wanted to rotate the board was to introduce a new user accessibility and cable management experience. When you rotate the board, all the connections are on top of the machine. You don’t have to turn the entire case around every time you want to connect something up. Or, if it’s under your desk, crawl under it and deal with a tangle of cables in the darkness. With the Omen, the all the connections are easily access just by lifting off the top panel. No tools are necessary.
TNBN: How does this accessibility theme play out on the Envy?
Mark: It’s more of a software solution. User accessibility is expressed with the Envy’s instant-on feature. You can access the Web, personal documents and media instantly, using Voodoo IOS, without waiting for the whole system to power up.
TNBN: Ahh…a little Voodoo magic.
Mark: [CHUCKLES] Arthur C. Clarke said that “any sufficiently advanced technology is indistinguishable from magic.” From that perspective, there were a few things we wanted to do that added a “wow” factor to these computers. On the Envy, there’s a proximity sensor that recognizes when your fingers are on the keyboard and turns off the touchpad to avoid any accidental movement of the cursor. There’s also a palm sensor that turns on the keyboard lighting—and turns off to save power when your hands move away for period of time. And even if wireless isn’t available where you’re working, you can plug an Ethernet cable into a jack on the power brick and a point-to-point Wi-Fi connection is automatically established. We even developed optional facial recognition software for the Envy. The machine actually recognizes your face! That’s magic.
TNBN: Is there magic in the Omen?
Mark: OMEN has some nice surprises as well, such as the interior lighting that turns on like in a refrigerator. You can choose from 16 million different colored lighting schemes for underneath the machine, as well as different animated behaviors. It’s like having your own little light show.
TNBN: Mark, thank you for taking the time to chat with us. Hope we get to do this again soon.
Mark: You’re welcome. I’ll come back when we’ve got some new magic to share.
The Next Bench News: These days, the world seems to be all curves and soft forms. Yet, both the Envy and the Omen are square blocks and straight lines. Are you just trying to be different?
Mark Solomon: Voodoo is indifferent to trends, and by doing so has become a trendmaker in its space. But the new design language of Voodoo is more than just being different, it goes back to the brand tenets of what Voodoo is and how it fulfills the brand experience.
TNBN: What do you mean by basic design language?
Mark: All of Voodoo’s products share some common visual and experiential traits. Just like people in a family share certain characteristics—a chiseled jaw, a pointed nose—that are passed down from generation to generation.
TNBN: How do these traits manifest themselves in Voodoo’s products?
Mark: Being originally from HP, we had to study Voodoo of the past to ensure the new Voodoo was true to it’s roots. We discovered a couple of basic truths that are core elements that run throughout its products. First, alot of the products were square or geometric in form. So we decided to build on this family trait by updating and refining it. The result is that the Envy and the Omen share a monolithic form. They’re square blocks, with clean, straight lines and totally flat surfaces. Turn the Envy upside-down and it’s completely flat. There are no bump-outs or curves that you see in other notebooks. The same with the Omen. No extraneous shapes. It’s all business. We’ve taken the square block and made it very sexy.
TNBN: What’s the second basic truth you discovered about how Voodoo builds computers?
Mark: They use high quality materials. The new Envy and Omen take this to the next step by using what I call “performance materials.” For the Omen, we chose aircraft-quality aluminum. Not cast, but extruded. Not only is it lighter and stronger than steel or sheet metal, aluminum has really great thermal properties and dissipates heat more efficiently than other metals.
TNBN: What about the Envy, other than its square shape, it seems like an entirely different animal?
Mark: Vastly different, but also the same. It’s also made of a high-performance material: carbon fiber. A different material, but it shares some of aluminum’s characteristics: it’s ultra light and ultra strong. In order to create a notebook that’s just 0.70 inches thick, weighs less than 3.4 pounds and has a removable battery, there was no other way to do it. By using extruded aluminum and carbon fiber on these machines, it enabled us to design in higher performance—whether it’s super high-powered gaming on the Omen, or increased mobility on the Envy.
TNBN: The LCD screens on the Envy and the Omen are covered with a thick slab glass that goes from edge to edge. We’ve never seen this before.
Mark: It’s a subtle little design feature that emphasizes their clean flush lines. Also notice that the Envy and the Omen have LCD screens covered with a thick slab of glass that goes from edge to edge. It’s a subtle little feature, but it adds to their clean, flush lines.
TNBN: Beautiful. It accentuates the square, monolithic form you were talking about.
Mark: It’s very difficult to do and adds to the unmistakable quality of workmanship that goes into these machines. There are also exposed edges on other parts, as well. For instance, on the keyboard deck of the Envy. And on the Omen’s side panels. This effect only works when you’ve got tight engineering. Most manufacturers try to hide their exposed edges because it doesn’t look quite so sexy when you’re using sheet metal. But we wanted to show the quality and thickness of the materials we are using. The exposed edges also come into play in the personalization of the Envy and the Omen. They show the various layers of paint, wood and other materials that are and will be used to customize and personalize these machines.
TNBN: It’s almost like looking at the strata in a rock formation.
Mark: Exactly. Say a user has his Omen for four years and has applied different paints and surfaces to it during that time. He can see the entire history of his machine just by looking at the edges. You can go a little crazy with this, but you get the idea.
TNBN: Both machines also share a certain thin quality. Was this intentional?
Mark: Yes, we worked really hard to get both machines really thin. When you look at the Omen straight on, despite its mass, it’s thin. We didn’t use any trickery to accomplish this. In contrast, the HP Blackbird’s cantilevered design involves a little bit of optical illusion to hide its size. The only thing that might be construed as trickery in the Omen is the “hover” effect when viewing it from the side. But this actually serves an important function in the cooling of the interior components. This is also why we rotated the motherboard.
TNBN: Yes, we’ve been wondering why everything is turned around on the Omen. How did this novel idea come about?
Mark: Simple science… A proven scientific fact is that heat rises. We wanted to rotate the board 90 degrees to take full advantage of that concept. Why force heat through the front and back of the machine using energy-eating fans when you can accomplish the same thing using natural convection. Of course, we still have placed fans and liquid cooling in the Omen, but we are assisting the cooling process and, in theory, will have a quieter machine.
TNBN: Does anyone else do this on their machines?
Mark: Convection techniques have been employed, but, as far as I know, no one has rotated the motherboard on a large desktop. Another functional reason we wanted to rotate the board was to introduce a new user accessibility and cable management experience. When you rotate the board, all the connections are on top of the machine. You don’t have to turn the entire case around every time you want to connect something up. Or, if it’s under your desk, crawl under it and deal with a tangle of cables in the darkness. With the Omen, the all the connections are easily access just by lifting off the top panel. No tools are necessary.
TNBN: How does this accessibility theme play out on the Envy?
Mark: It’s more of a software solution. User accessibility is expressed with the Envy’s instant-on feature. You can access the Web, personal documents and media instantly, using Voodoo IOS, without waiting for the whole system to power up.
TNBN: Ahh…a little Voodoo magic.
Mark: [CHUCKLES] Arthur C. Clarke said that “any sufficiently advanced technology is indistinguishable from magic.” From that perspective, there were a few things we wanted to do that added a “wow” factor to these computers. On the Envy, there’s a proximity sensor that recognizes when your fingers are on the keyboard and turns off the touchpad to avoid any accidental movement of the cursor. There’s also a palm sensor that turns on the keyboard lighting—and turns off to save power when your hands move away for period of time. And even if wireless isn’t available where you’re working, you can plug an Ethernet cable into a jack on the power brick and a point-to-point Wi-Fi connection is automatically established. We even developed optional facial recognition software for the Envy. The machine actually recognizes your face! That’s magic.
TNBN: Is there magic in the Omen?
Mark: OMEN has some nice surprises as well, such as the interior lighting that turns on like in a refrigerator. You can choose from 16 million different colored lighting schemes for underneath the machine, as well as different animated behaviors. It’s like having your own little light show.
TNBN: Mark, thank you for taking the time to chat with us. Hope we get to do this again soon.
Mark: You’re welcome. I’ll come back when we’ve got some new magic to share.