Simply put, the alcohol-free fountain solution replaces alcohol or isopropyl alcohol with other non-toxic chemical components. However, the industry also refers to the dampening solution with lower alcohol concentration as alcohol-free fountain solution. In the traditional concept, alcohol dampening solution plays a key role in high-efficiency and high-quality offset printing. However, although alcohol dampening solution has many advantages, it still makes everyone “deep and fearfulâ€, which is due to the main component of alcohol dampening solution (isopropyl alcohol). IPA) is toxic and volatile, not only polluting the environment. When the concentration of IPA per unit volume in the air reaches or exceeds 400ppm, human health is also obviously threatened. Below this concentration, the human body is often in contact with it. In chronic poisoning, it will induce occupational diseases that are common in printing companies.
Calculation of the use cost of alcohol-free fountain solution and alcohol fountain solution
Direct cost calculation
Take the use of our company's dampening solution as an example.
(1) Single cylinder water tank cost
Take the calculation of two printing machines with comparable output of our company.
The company's No. 1 printing machine uses alcohol dampening solution. The total capacity of the printing machine water tank is 60 liters. The purchased dampening solution has a capacity of 20 liters per barrel and the unit price is 22 yuan/liter. The alcohol has a capacity of 18 liters per barrel and the unit price is 10 yuan/liter. The amount of dampening solution added during printing is 3% (sometimes depending on the float), and the amount of alcohol added is 12%.
Alcohol dampening solution single cylinder cost = dampening solution cost + alcohol cost = 3% × 60 × 22 + 12% × 60 × 10 = 39.6 + 72 = 111.6 (yuan)
The company's No. 2 printing press uses alcohol-free fountain solution. The total capacity of the printing machine water tank is 60 liters. The purchased dampening solution has a capacity of 20 liters per barrel, the unit price is 38 yuan/liter, and the amount of dampening solution is 3.5%. 5%.
In the same way, the cost of the alcohol-free fountain solution single cylinder = the cost of the fountain solution + the cost of alcohol = 3.5% × 60 × 38 + 5% × 60 × 10 = 79.8 + 30 = 109.8 (yuan). It is known that the alcohol-free dampening solution can save more than the alcohol dampening solution single cylinder: 111.6-109.8=1.8 (yuan).
(2) “Water†cost throughout the year
The following is a calculation of the annual operating cost of the fountain solution based on the current usage. The company implements a 6-day working system and calculates it on a 26-day working day each month.
The No. 1 printing machine uses 2 barrels of alcohol per day. The cost of alcohol per day is 18×2×10=360 yuan. The monthly alcohol cost is 360×26=9360 yuan. The annual alcohol cost is 9360×12=112320 yuan.
The No. 1 printing machine uses 2 barrels of dampening solution per month. The monthly dampening solution costs: 20×2×22=880 yuan, and the annual dampening solution cost: 880×12=10560 yuan. In the above two totals, the annual alcoholic fountain solution cost of the No. 1 printing press is=112320+10560=122880 yuan.
In the same way, the No. 2 printing machine uses 28 barrels of dampening solution every year. The annual cost of dampening solution is 20×28×38=21280 yuan, and the annual alcohol consumption is 252 barrels. The annual alcohol cost is 252×18×10=45360 yuan.
In the above two totals, the annual alcohol-free fountain solution cost of No. 2 printing press = 21280+45360=66640 yuan.
It can be concluded that the No. 2 printing machine can save costs only one year in the fountain solution than the No. 1 printing machine: 122880-66640=56240 yuan. Therefore, the use of alcohol-free fountain solutions helps to reduce production costs.
2. Indirect cost analysis
The above is only a direct cost, and there are many hidden costs that can be calculated by formula when using alcohol fountain solution.
(1) The direct cost calculation does not include the cost of alcohol evaporation during the use of alcohol fountain solution. When the business is busy, our company's customary practice is to add new dampening solution and alcohol according to the amount of one week after washing the water tank on Monday. The amount of alcohol volatilization can be imagined.
(2) The alcohol dampening solution needs to be cooled and cooled when it is used. The amount of electricity used to cool the dampening solution cannot be accurately calculated, but it is definitely a small expense.
(3) Because of the large amount of alcohol dampening solution used, the labor cost and material cost of cleaning the water tank and adding dampening solution and alcohol to the water tank are also very large.
In summary, the use of alcohol-free fountain solution has a considerable cost advantage.
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