[Abstract] This article discusses how the tobacco industry enterprises in the new era are trying hard to reduce manufacturing costs in the new situation. The application process of the PVDC coating film instead of the traditional packaging method is specifically described.

I. Introduction

As we all know, the current direct competition and challenges faced by China Tobacco’s tobacco giants facing foreign tobacco giants are in a transitional period toward the era of market economy. How do tobacco industry companies in the transition period enhance competitiveness in increasingly fierce market competition and control manufacturing costs? Has become the key to the key. For a long time, regardless of the level of cigarette production, cigarette packaging products have been using the “box label + packaging film” packaging method, for the low profitability or even loss of the four or five categories of low-grade cigarettes, the cost of packaging costs accounted for the proportion of Too large, efforts to reduce the packaging costs of the four or five types of cigarettes have become an inevitable choice for cigarette manufacturers. Under the premise of not reducing the quality of cigarettes, how to reduce the manufacturing cost has become the main research direction of the company in recent years. Under the macroscopic decision and strong support of the provincial bureau (company), after repeated demonstrations by the majority of technical personnel, the use of PVDC coating film directly The double-transparent packaged low-grade cigarettes packaged outside the small-size cigarette packs were produced in our factory in March 2003 and put on the market as scheduled, which has made great contributions to the enterprises' control of the consumption and reduced consumption.
Double transparent packaging means that a certain number of small packets of cigarettes (usually 10 boxes) are arranged neatly, and instead of using strips of label paper, transparent packaging materials are used to wrap them into strips. How to choose a transparent packaging material can not only maintain and extend the shelf life of cigarettes, but also does not affect the appearance quality of cigarettes. At the same time, it can be accepted by the market and become the key to using double transparent packaging. After repeated trials and analysis, PVDC coating became our first choice.

Second, feasibility analysis

1, physical and chemical performance analysis
The PVDC coating film refers to a film formed by coating a PVDC emulsion on a BOPP film and drying it. PVDC coating film has excellent properties such as high barrier, high fragrant, strong abrasion resistance and high gloss, which is unmatched by ordinary BOPP. Solid PVDC Since the invention of the US Dow Chemical Company in 1930, PVDC has become the "high" version of the name, and the packaging industry has called it the "Queen" of high-barrier materials. PVDC's gas barrier and moisture resistance are the best among plastics, and it is excellent in fragrantness. Test data shows that BOPP film with 23-μm-thick PVDC coating has equivalent barrier properties of 1300 μm thick uncoated BOPP film. . Because the chemical structure of PVDC is very different from that of BOPP, the two cannot be heat-sealed with each other, ensuring that during the packaging process of cigarette caddy, it will not adhere to the ordinary BOPP film that is in contact with the small box and the coating. Has a good heat sealing performance, making the seal flat and dense. PVDC has a stable friction coefficient, good anti-static performance, and excellent mechanical operation adaptability to ensure it is suitable for any package speed. Based on the above analysis, we can see that PVDC has excellent physical and chemical properties, making it possible for us to replace traditional cartridge packaging.

2. Cost Analysis The focus of the use of double transparent packaging is to reduce manufacturing costs. We analyzed the cost of the two types of strip packaging: Strip area: 0.34×0.29=0.0986m2 Area used in one box: 250×0.0986 =24.65m2/conventional packaging method (BOPP+ box trademark) double transparent packaging (PVDC coating film)
Weight of film 20g / m2 32g / m2
Per ton film area 50000 m2 / ton 31250m2 / ton film price 18,000 yuan / ton 28800 yuan / ton single box film cost 18000÷50000×24.65=8.87yuan/box 28800÷31250×24.65=22.72yuan/carton box Trademark cost 0.3 RMB/pc x 250 pcs/box = 75 pcs/box/
Cumulative cost 83.87 yuan / box 22.72 yuan / box

From the above table, it can be stated that the use of double transparent packaging, in theory, a single box can save manufacturing costs 61.15 yuan, according to the annual output of 100,000 boxes, can save 6.115 million yuan.

3. Market Analysis With the low-cost products that meet the quality requirements, whether or not it can gain the recognition of consumers and the market has become the key to the problem. As we all know, double transparent packaging is mainly used in the packaging of low-grade cigarettes, while low-grade cigarettes are mainly targeted at rural markets with a high proportion of low-income people. The 40 million rural population in Anhui Province determines that low-grade tobacco has a broad market base. At the same time, the consumer groups at this level mainly focus on the inherent quality of cigarettes, and in addition, they rarely purchase articles in the process of consumption. The consumption habits determine that as long as the internal quality of cigarettes is not reduced, the packaging of small boxes is not changed, and only the package is changed. Packaging does not affect the sale of the brand's cigarettes.

Third, the implementation of transformation

Through repeated demonstration of physical and chemical properties, costs, and market demand, we are confident that the transformation will be successful. Two different types of packaging units for B1 and GDX1 have been designed for retrofitting:

(1) GDX1 unit 1, electrical appliances: Closed glue tank liquid level detection, glue cylinder off-line detection, strip box level detection, strip box paper left-right alignment and presence detection.
2. Mechanical: Remove the side movable corner box of the barrel, replace the side baffle of the barrel and the first lifting plate of the CT entrance; adjust the width of the conveying channel, shorten the length of the channel by adjusting the lower screw of the machine; adjust the spacing of the rotating folder; adjust Raise the distance between the push cylinder and the hoist; adjust the width of the CV strip passage.

(B) B1 unit 1, electrical appliances: Close the detection of the strip box in place; convert the strip box count proximity switch to the left side of the push plate, ensure that each cigarette is counted and reset once, so that the synchronization gear is in the register signal Under the action of the packaging action.
2. Machinery: Remove the strip box turret die and long-edge angler; remove the transparent chevron on the original channel and replace it; adjust the large transparent turret; adjust the double-side sealing iron and tobacco at the exit of the cigarette Transparent angler; adjust the position of the transparent long edge heat seal.

Through continuous practice, we have concluded a set of standardized reform programs that can be completed within half an hour. The transformed equipment is operating normally and the product quality is stable.

IV. Summary <br> The packaging products have been in production since March. Our factory has successively produced about 50,000 boxes of low-grade smoke in double-transparent packaging. After it was put on the market, it responded well. The market share increased month by month, without lowering the internal volume of cigarettes. Under the premise of quality, the manufacturing cost is saved by about RMB 3 million, which opens up a new road for consolidating the rural market and further expanding market share.
The road is long and far-reaching. With the rising global environmental protection calls, the road of sustainable development has become the only way for science and technology and future industry and commerce. Pursuing environmentally friendly packaging materials and implementing “appropriate” packaging are the direction of the company’s pursuit. Our next research goal. (Text/Zhang Hui)