INDUSTRIAL VISIT
to NEXTGEN PRINTERS for PACKAGING DESIGN
KHUSHBOO CHORARIA F&LA 2014-18 ROLL NO. 11
OBJECTIVE The mere objective of making this report is to analyse the working of a packagind industry and understand the working function of the machines used by them. One had to document all this into a informative report for personal understanding and future reference.
CONTENTS ABOOUT THE COMPANY Introduction Products Made
01
INFRASTRUCTURE OF THE COMPANY Products Current Scenario
02
MACHINE USED in the company Offset Printing Machine Hot Foil Stamping Machine Coating Machine Laminating Machine Hydraulic Trolley Machine Screen Printing Machine Sample Maker CP Machine Paper Cutting Machine Knife Sharpening Machine Pile Turner Machine Folding and Gluing Machine Line Packing and Sealing Machine Window Patching Machine V-notch Window Machine
03
ABOUT THE COMPANY NEXTGEN PRINTERS PVT LTD., founded in the year 2008, was the first to set up a printing and packaging unit in the state of Sikkim, India. The state of the art Factory at Majhitar, Rangpo, East Sikkim, has been set up for manufacturing different types of folding cartons & Corrugated Boxes (Shippers) with an investment of over INR 200 Million. The first phase being commissioned boasts of a capacity build-up capable of converting 200 MT of Paperboard per month. Their hi-tech plant is equipped with the most modern and sophisticated production machinery imported from MITSUBISHI of Japan & BOBST of Switzerland along with supporting machinery being the best in the country in yester years. PRODUCTS : â– â– Mono Cartons, Liner Cartons, Window Patch Cartons, Erected Cartons, Hard Boxes, Blisters cards, Inserts, Labels.
INFRASTRUCTURE of the company The Sikkim Unit, now an ISO 9001:2008 certified unit has since been catering to a wide range of customers ranging from the Pharmaceutical Giants of the Country, the local Liquor Industry, the State Cooperative and the local small traders and manufacturers. Keeping in mind the requirements of the area, the unit was set up with the following state-of-the art machines: PRODUCTS : Mitsubishi D-2000 LS 4 Colour Offset Press Mitsubishi Daiya-I Single Colour Offset Press Proteck Offline UV & Aqua Coater Bobst Novacut 106 Die Cutters Bobst Ambition A-1 Folder Gluer Alpha Omega Folder Gluer Pratham Sheet fed Paper Folders for Literature Heidelberg Hot Foil Stamper Paper & Board Cutting Machines from Proteck & Sato Screen CTP ESKO Pre Press Workflow CURRENT SCENARIO : They took another bold & giant step forward in setting up Eastern India’s FIRST fully integrated UV Press for specialized Packaging Solutions. This unit in Howrah District of West Bengal with its range of specialised automatic machinery is bound to make people wonder aloud, as the world class packaging produced, makes the end products stand out on the shelves. To give our customers this high class packaging, we come with a host of machinery which claim to be the first of its kind in Eastern India.
Machines used OFFSET PRINTING MACHINE It is a commonly used printing technique where an inked image is transferred (or “offset”) from a plate to a rubber blanket, then to paper. The offset process is a lithographic process. Lithoghraphy is a process based on the repulsion of oil and water. PROcess : ■■ ■■ ■■ ■■ ■■
the inking system (ink fountain and ink rollers); the dampening system (water fountain and water rollers); the plate cylinder; the offset cylinder (or blanket cylinder); the impression cylinder.
An image that is offset printed is separated into its fundamental colors. The brochure would be broken down into the primary printing colors; cyan, magenta, yellow and black (CMYK). Thanks to computers this process has become easier. The image is broken down into these four colors and four seperate plates are made. A plate is made up of areas that are receptive to grease and areas that are receptive to water. The areas receptive to grease hold onto the ink while the other areas attract water and repel the ink. These plates are then put on to a press. From the ink fountains, the press pulls in the ink and puts it onto the plate. The press applies great pressure to the plate and the ink imprints the image from the plate onto a rubber blanket. The image is then pressed onto the paper off the blanket to make a print. All this happens really fast and many impressions can be made from one set of plates. It is a very efficient process and lends itself very well to long runs over a long period of time.
HOT FOIL STAMPING MACHINE In principle, hot foil stamping is the process of using heat and pressure to apply metallic foil or holograms to materials such as light papers, carton board, laminated board, plastics and corrugated board. The term hot foil stamping encompasses: • Simple flat foil stamping • Deep embossing or embossing combined with foil stamping • Hologram and holographic foil application • Foil stamping combined with micro & structural embossing PROcess : In a hot stamping machine, a die is mounted and heated, with the product to be stamped placed beneath it. A metallized or painted roll-leaf carrier is inserted between the two, and the die presses down through it. The dry paint or foil used is impressed into the surface of the product. ■■ ■■ ■■ ■■ ■■
Die is a metal plate with the reversed image raised from the surfaceTypically these will be made of brass, copper, or magnesium. Foil is generally manufactured on a film roll made up of pigment, clear mylar, and a heatactivated adhesive. Substrate is what you want to foil stamp.
WORKING : Foil Stamping comes down to three things: Heat, Pressure, and Time. The foil film is positioned between the heated metal die and the material receiving the foil. The die presses the foil onto the material and the heat activates the adhesive. There are three differing operating principles found among foil stamping machines, commonly called flat-flat, round-flat, and round-round.
COATING MACHINE The roll of substrate, such as: paper, cloth, leather, aluminum foil, plastic film, plastic coated specific function, such as paint or ink, and after drying the winding. Automatic coating machine works: for screen printing version of automatic coating machine working principle is the same, but its performance under different models and different manufacturers and different. Screen coating machine in a vertical rack has a device to clamp the screen frame. PROCESS : The coating process consists of applying a coating material to a moving web of flexible sub■■ strate. ■■ The carrier substrate may be paper, film, or aluminum foil and the resulting material’s ■■ additional properties will vary depending on the required application and on the material’s ■■ end-use. ■■ The benefit of coating is that it delivers to the substrate enhanced aesthetic and physical ■■ properties derived from the coating material. ■■ ■■ TYPES : Varnish: to impart a clear, glossy surface to the web ■■ Cold seal: used mainly for products where normal heat sealing cannot be used (chocolate ■■ bars, ice-creams, etc) ■■ PVdC coating: used to improve the barrier properties of transparent films, as well as the ■■ gloss of printed films ■■ ■■
LAMINATION MACHINE Lamination is the technique of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance or other properties from the use of differing materials. A laminate is a permanently assembled object by heat, pressure, welding, or adhesives TYPES : ■■ Wet lamination: ■■ where the bonding agent is still in a liquid state when the webs are joined together. It is ■■ mainly used to produce a paper-aluminum foil laminate used in flexible packaging. ■■ Dry lamination: ■■ where the bonding agent, dissolved into a liquid (water or a solvent), is applied to one of the ■■ webs, before being evaporated in the drying oven. The adhesive coated web is laminated to ■■ the other under strong pressure and using heated rollers, which improves the bond strength ■■ of the laminate ■■ Wax lamination: ■■ where the bonding agent is a wax or hot melt and is applied in a molten state onto one of the ■■ two substrates. This process allows the production of paper-paper or paper-aluminum foil ■■ laminates that are widely used for the packaging of biscuits and bakery products ■■ Solventless lamination: where the adhesives used do not contain solvents. Solventless adhesive generally indicates a specific type of adhesive composed by two components reacting with each other and consequently not requiring drying.
HYDRAULIC TROLLEY MACHINE A jack is a device that uses force to lift heavy loads. The primary mechanism with which force is applied varies, depending on the specific type of jack, but is typically a screw thread or a hydraulic cylinder. Jacks can be categorized based on the type of force they employ: mechanical or hydraulic. Mechanical jacks, such as car jacks and house jacks, lift heavy equipment and are rated based on lifting capacity (for example, the number of tons they can lift). Hydraulic jacks tend to be stronger and can lift heavier loads higher, and include bottle jacks and floor jacks. WORKING : Hydraulic jacks depend on force generated by pressure. Essentially, if two cylinders (a large and a small one) are connected and force is applied to one cylinder, equal pressure is generated in both cylinders. However, because one cylinder has a larger area, the force the larger cylinder produces will be higher, although the pressure in the two cylinders will remain the same. Hydraulic jacks depend on this basic principle to lift heavy loads: they use pump plungers to move oil through two cylinders. The plunger is first drawn back, which opens the suction valve ball within and draws oil into the pump chamber. As the plunger is pushed forward, the oil moves through an external discharge check valve into the cylinder chamber, and the suction valve closes, which results in pressure building within the cylinder.
SCREEN PRINTING MACHINE Screen printing is a printing technique whereby a mesh is used to transfer ink onto a substrate, except in areas made impermeable to the ink by a blocking stencil. One color is printed at a time, so several screens can be used to produce a multicoloured image or design PROCESS : The screen printing process uses a porous mesh stretched tightly over a frame made of wood or metal. Proper tension is essential to accurate color registration. The mesh is made of porous fabric or stainless steel mesh. A stencil is produced on the screen either manually or photochemically. The stencil defines the image to be printed in other printing technologies this would be referred to as the image plate. TYPES : If the item was printed on a manual or automatic screen press the printed product will be placed on a conveyor belt which carries the item into the drying oven or through the UV curing system. Rotary screen presses feed the material through the drying or curing system automatically. Air drying of certain inks, though rare in the industry, is still sometimes utilized.
SAMPLE MAKER CP MACHINE Suitable for colour printing factory, packing plant packaging product design proofing sample maker, Reduce production costs, improve business efficiency & competitiveness, strengthen enterprise management. The integration of the process before printing) of various packaging products .solving sample maker proofing, printing, die cutter, make-up, operate open paper.all pre-press process quantitative management, transparency, experience and reduce other human factors to impact of the enterprise. PROCESS : ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■
Use professional design software to draw box Import box file to machine for producing white box-type Confirm the structure and size from the white box-type samples Paste the structure to the graphic design pattern. Using color three-dimensional simulation function to confirm the overall effect for Box-type structure and the of graphic design Opening paper and makeup through box-type structure to calculate the cost Maintaining graphic design make-up Consistency by a key functional and structural make-up Automatically generated required CTP data to ensure print and box-type design consistent Automatically generated required cutting data to ensure box-type die cutter and design consistent
PAPER CUTTING MACHINE Fully Automatic Hydraulic Type Paper Cutting Machine is manufactured using latest tools and equipment. In compliance with the specifications provided by the clients, they can be customized. In addition to this, this machine is highly appreciated for its easy operation, low maintenance and longer serving life. FEATURES : ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■
Programmes: The Storage capacity of the programmer is 99 programmes and one programme capacity is 99 cuts in this machine. The accuracy of the programme is 0.01 mm 0.001 inch. Conversion from mm to inch fraction is also possible. The programme controls the backguage with double speed. The machine has a 1:6 ratio motor is installed for very accurate clutch brake system. Back Gauge Accuracy: Control through upper moving system Perfecta (Seypa) Type. The screw is running on ball bearings. Back-gauge guide moves at grinded pillar. Drive Gear Box: The worm gear drive has ground worm and needs less power than any other conventional drive. The gears are running in oil bath. Air Cushion Table: Helps to move the paper stack very easily. Hydraulic Clamp: An advance design, together with new technology concepts have account for increasing rationalization and the consequent performance requirements. Friends range now has a new drive Mechanism for clamping. The special features of this machine are double clamping pressure and gentle setting of the clamp on the paper to be cut. The clamping pressure is adjustable with a knob positioned under the table at a convenient place. Indication Light: A Beam of light falls across the Knife width, on the paper to be cut without lowering the clamp. This ensures proper cutting. Knife Changing Device: The knife can be changed easily by lift system and safely by a single operator. Photo Electric Safety: Guard A set of infra red light beams are projected in front of the cutting zone just above the table to avoid an accident.
KNIFE SHARPENING MACHINE The Cutting Knife Sharpening Machines are ideally designed for sharpening of knife for cutting machines. The unparalleled quality and effectual performance has made the Knife Sharpening Machines ideal for various industrial sectors. Additionally, the array also includes Automatic Knife Sharpening Machines that are configured with the latest features and comes at affordable rates. SALIENT FEATURES : ■■ ■■ ■■ ■■ ■■ ■■ ■■ ■■
Most suitable for grinding knifes and blades of paper cutting machines, plastic cutting machines, metal cutting shears, etc. Electro-Magnetic 360o Swiveling Table for flat, bevel and multi surface grinding Durability High Precision High quality Easy Operation Low Noise High Productivity
USED FOR : ■■ ■■ ■■ ■■ ■■ ■■ ■■
Perfecta Cutting machines Wolenerg Rotary Sheet Cutting Knife 3 Knife Trimmers Foam Atlas Muller Martini
PILE TURNER MACHINE Originally the machine was used just for turning paper, to replace manpower by machinery. Nowadays it is used for Airing, Dust removing, Drying, Aligning, Jogging. Pile turners are available as semi-automatic or fully-automatic versions optionally. Turning is done by hydraulically lifting the pile to the horizontal position and subsequently rotating it through 180°. Reproducible pile treatment is possible by storable airing programs. The installation of protective fences with light barriers and the motorized-pneumatic aligning gauge with paper recognition enables the fully automatic operation. EQUIPPED FOR 3 WORKING CYCLES ■■ Turning the paper/board pile ■■ Airing, aligning and jogging the pile ■■ Airing, aligning, jogging and turning the pile
FOLDING AND GLUING MACHINE The folding and gluing process transforms a piece of flat material into a finished product such as a box, envelope, or promotional item. This is achieved by folding the blank along pre-creased lines and applying the adhesive that will hold the product together. Folder-gluers are suitable for processing a wide range of materials including solid board, plastics, metalized varnished boards, litho-laminates, micro-flutes, and corrugated board. Their use is seen mainly in the packaging industry where they transform flat blanks into straight-line, crash-lock bottom, or multi-point boxes. GLUING Not all glue wheels are created equal, and the large wheel on your folder-gluer has been specifically developed to ensure accurate glue delivery without glue splashing off, even at the highest speeds. ■■ Oversized stainless steel glue wheel ■■ Unique brass double scraper with micro-metric adjustment ■■ All components easily removable FOLDING Smooth, progressive folding whatever the product. The final fold of your product needs to be accurate, whatever size and substrate you are running. • Automatic belt tensioning • Height adjustable • Choice of folding • Minimum folding device
LINE PACKING & SEALING MACHINE It is a machine with auger filling system and is suitable to pack spices, flours, detergent powder, protein powder, custard powder, milk powder, instant drink powder, gulab jamun mix & food premixes in lined cartons. On specification basis it has 14 station with a packaging range of 50gms to 250 gms/200gms to 500gms and based on the production speed it can make 15 to 20 cartons per minute.
WINDOW PATCHING MACHINE It is a high quality and high performance machine that is used for film patching of package with or without theqp window such as wine box,gift box,napkin box and cosmetic box.It also performs the function of paper gluing,film cutting and paper collection before folding boxes
V-NOTCH WINDOW MACHINE It basically applies to 90° “V” groove cutting for aluminium and plastic profiled bar which is clamped and cut by pnematic drive.It has characteristic of simple operation,high safety,exact cutting dimension and convient maintenance.