The exercise books we use daily come from a sophisticated and efficient fully automatic machine that operates seamlessly from raw paper rolls to finished products. In the modern paper manufacturing sector, such production lines are reshaping the industry with their advantages in intelligence and automation. Let's take a closer look at the entire process of exercise book production.

1. Unwinding and Preprocessing: The Starting Point of Production
   

   At the beginning of production, paper rolls with a diameter of over 1.2 meters are transported to the unwinding rack of the production line using forklifts. The equipment automatically detects the inner diameter of the paper roll and secures it accurately to ensure stable unwinding.

   During the unwinding process, intelligent devices adjust the paper tension in real-time to prevent issues like wrinkles or breaks. Even as the paper roll nears its end, the production line can transition smoothly—an internal warning system signals staff to prepare for a roll change, and the line automatically stops after completing the current batch, ensuring an efficient and fluid process.

   
   

2. Printing and Line Ruling: Adding Practical Functionality To Paper

   Once the paper enters the printing and line ruling phase, it’s like stepping into a "function customization workshop." The printing unit supports 2+2 or 3+3 color flexographic printing, capable of simultaneously printing horizontal and grid lines. Whether it’s standard exercise book formats or custom designs, everything is rendered.

   For changing print designs, a plate-based flexographic printing method is used, where new plates are quickly adhered to the printing roller with double-sided tape, allowing easy switching between different line spacing and patterns. This method is user-friendly and easily accommodates diverse production needs.

   
   

3. Cutting and Collecting: Precise Cutting and Intelligent Assembly

   After printing and ruling, the paper moves to the cutting and collecting stage. The cross-cutting unit operates like a precise craftsman, with high-speed rotating blades cutting the paper at a high frequency. Whether for standard sizes like A4 or B5, or for custom specifications, the cuts are executed with minimal error.

   The cut sheets are transported on a conveyor belt to the counting and collecting unit, where they are neatly stacked in groups of 7 to 50 sheets. Pre-printed covers are then accurately inserted, completing the combination of "core paper + cover."

   
   

4. Binding and Forming: The Core Process Determining Quality
   

   Once the paper is assembled, it enters the crucial binding and forming stage. In the wire stitching section, multiple stitching heads work in tandem, rapidly moving between stacks of paper to automatically bend and bind the wire, completing up to 50 bindings per minute to ensure the sheets are securely fastened.

   After binding, the paper undergoes folding and spine pressing. Under the control of a servo motor, folding rollers compress the stack precisely, ensuring the spine is neatly aligned. A mechanical spine pressing device uses adjustable pressure rollers to flatten and solidify the spine, enhancing the book's appearance and durability.

   
   

5. Three-sided Trimming: Creating a Refined Appearance

   At this point, the exercise book is nearly complete, and the trimming steps will refine its appearance. The three-sided trimming unit first trims the front edge with a long knife, then uses side knives to separate the entire stack into individual books. Meanwhile, a waste suction device cleans up trimmings in real time to keep the production line tidy.

   
   

6. Intelligent Control System: The "Smart Brain" of the Production Line

   Throughout the entire production process, the intelligent control system plays a vital role. Through a human-machine interactive touch panel, it monitors production speed, output, equipment status, and more in real time. If any anomalies occur, it immediately issues alerts, allowing staff to respond promptly.

Additionally, the production line features a modular design, enabling companies to flexibly add functional modules according to their needs, easily adapting to diverse market demands.

With over 90% automation, the fully automated exercise book production line produces student exercise books in large volumes, achieving a 70% efficiency increase compared to traditional methods while significantly lowering maintenance costs. If you're interested in the exercise book production line or have customization needs, feel free to contact us to explore more possibilities.