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Training report paharpur 3P Himanshu Ahuja

Industrial Training Report , Paharpur 3P , Gravure Printing

Training report paharpur 3P Himanshu Ahuja

  1. 1. A Training Report ON PaharPUR 3P Department of Printing Technology GURU JAMBHESHWAR UNIVERSITY OF SCIENCE & TECHNOLOGY HISAR, HARYANA Submittedto: Submittedby: Himanshu Ahuja Roll No.11032006 B.Tech. (PT)
  2. 2. 2 ACKNOWLEDGEMENT Without any hesitation I can say that the training session which I had for period of 6 weeks could not be complete successfully without the generous assistance of number of people. I have an obligation to acknowledge these all people who gave valuable cooperation, assistance and advices to success my training. I am highly thankful to Mr. Satendra Katiyar, the Deputy Manager of printing department of PAHARPUR 3P For giving me the opportunity to complete my training in their esteemed organization. I am extremely grateful to workers, engineers, and unit heads of Paharpur 3P industry for sharing their valuable knowledge with me and other trainees. I take this opportunity to express my gratitude towards Prof. Dharmender Kumar, Chairman, Department of Printing Technology and Mr. Anjan Kumar Baral. Incharge, Mr. Pankaj Kumar, Advisor, Training and Placement, Department of Printing Technology for allowing me to do my training in the PAHARPUR 3P and for their timely help. I am indebted to the entire teaching staff especially Mr. Ambrish Panday, Lecturer, Dept. Of Printing Technology ,Mrs. Vandana Gupta and Mr. Arohit Goyat for sharing their knowledge and experience with me and making the training pleasurable and memorable part of my life. The final tribute and appreciation are reserved for my family members, my colleagues and my senior students for the help they gave me in the preparation of this document.
  3. 3. 3 PREFACE Industrial training is the boom for the students as they expose the industry and get a chance to study the working of most modern equipment and the methodology of doing jobs. Forthebetter understandingofthepracticalsituationinindustry,theexperience gained fromtraining is vastlyimportant. It is an extraordinary opportunity to experience practical industrial environment, work discipline, team work, time management,qualitycontrollingandtoobtainaclear understandingofthe theoreticalknowledge whichwas gatheredat the university. I got my training in Paharpur 3P, Which is one of the most renowned industries in the field of “Gravure” printing and Flexible Packaging. Factory Manager: - Mr. Manoj Bisht Deputy Manager: - Mr. Satendra Katiyar Assistant Manager: - Mr. Raj Kumar Panday
  4. 4. 4 DECLARATION I, Himanshu Ahuja student of B.Tech of GURU JAMBHESHWAR UNIVERSITY OF SCIENCE AND TECHNOLOGY ,Hisar hereby declare that I have completed my Six Weeks Industrial Training at“ Paharpur 3P “. It is my original Training Report and the same have not been submitted earlier for any academic purpose. The information submitted is true and original to best of my knowledge. (Himanshu Ahuja)
  5. 5. 5 Introduction ‘What is Gravure Printing?’ Rotogravure printing or just simply gravure printing is a type of intaglio printing process which uses a rotary printing press. It involves engraving an image onto a copper plated steel cylinder base. The first step is to create a cylinder with an engraved image for each color that makes up the design. The engraving process will create on the cylinder surface the cells that will contain the ink in order to transfer it to the substrate (film or paper). Since the amount of ink contained in the cells corresponds to different color intensities on the substrate, the dimensions of the cells must be carefully set: deeper cells will produce more intensive colors whereas less deep cells will produce less intensive ones. A rotogravure printing press has one printing unit for each color, typically CMYK or cyan, magenta, yellow and key (printing terminology for black), but the number of units varies depending on what colors are required to produce the final image. There are five basic components in each color unit: an engraved cylinder (AKA “Gravure cylinder”) whose circumference can differ according to the layout of the job; an ink fountain or reservoir; a doctor blade; an impression roller; a dryer.
  6. 6. 6 ‘How does it work?’ The ink is applied directly to the cylinder and from the cylinder it is transferred to the substrate. While the press is in operation, the engraved cylinder is partially immersed in the ink fountain, filling the recessed cells. As the cylinder rotates, it draws ink out of the fountain with it. Acting as a squeegee, the doctor blade scrapes the cylinder before it makes contact with the substrate, removing excess ink from the non-printing (non-recessed) areas and leaving in the cells the right amount of ink required: this tool is located quite close to the substrate so that the ink left in the cells does not have enough time to dry. Next, the substrate gets sandwiched between the impression roller and the gravure cylinder: this is where the ink gets transferred from the recessed cells to the substrate. The purpose of the impression roller is to apply force, pressing the substrate onto the gravure cylinder, ensuring even and maximum coverage of the ink. The capillary action of the substrate and the pressure from impression rollers force the ink out of the cell cavity and transfer it to the substrate. Then the substrate goes through a dryer because it must be completely dry before going through the next color unit and absorbing another coat of ink. Image Generation. 4 Color PROCESS Printing / CMYK The image is separated into 4 different color values Cyan / Magenta / Yellow / Black Individual colors are printed as dots at varying densities Individual dots combine to form additional unique colors In Packaging printing, 4 color process is typically combined with line colors to accurately represent trademarks and logos and to maintain color consistency over large areas of solid colors The number of final colors in a design is nearly limitless
  7. 7. 7 Characteristics of Gravure Publication Printing The simplicity of the process helps make Gravure the fastest of the printing processes, the web runs at the greatest speed. The stability of the press makes it possible to print very wide webs. Gravure Printing suffers less downtime, and there is less wastage in comparison to other printing process. The combination of speed, width, and low downtime produces very high productivity and compensates for the relatively high cost of preparing a cylinder. The cost of preparing a cylinder is obviously less important on long runs and better print quality. The combinations of speed, width, & low downtime have big/ volume publication produced to look as alternate for their processes. Advantages:  high quality over long print runs  inline process possible  100 % seamless printing  excellent design reproduction  high quality of halftone image and gradation  excellent quality with metallic ink  combination of solvent and water-based ink  Suitable for various qualities of board / paper / foil.
  8. 8. 8
  9. 9. 9 About “Paharpur 3P” The Origin In the late 80's and early 90's, the flexible packaging in industry was evolving and was driven by the lubricant and tobacco industries. Paharpur 3P was the brainchild of Mahendra Swarup (Founder Chairman of the group) who was looking for a sunrise sector and seeing the opportunity and the growth rates (35- 40 percent annually) in the industry, decided to diversify into flexible packaging with a start-up unit in Sahibabad Industrial Area. That is how Paharpur 3P originated in the year 1994, with a green field project having modern state of the art technology imported from Europe. Since then Paharpur 3P has come a long way under the visionary leadership of Gaurav Swarup, Chairman of the company. Plant Preview Paharpur 3P is situated on an 18 acres plot on Delhi – Uttar Pradesh border wherein 33 percent of the area is utilized for corporate office and manufacturing / storage facilities. And the balance area is maintained under green cover reflecting the group's penchant for environmental safety and beauty. Company uses natural ventilators for air circulation in plant and storage areas and makes effective use of natural light. Rain water harvesting system has been put in place and ground
  10. 10. 10 water levels and quality of ground water are measured through PIZO meters. The water discharged from cylinder making department is treated through effluent treatment plant and is re- used for irrigation. The manufacturing operations for flexible packaging in the plant includes pre-press, plating, cylinder engraving, printing, lamination, extrusion coating, slitting, blown film plant, pouch making, bag making and ink making. Paharpur follows the ISO 9001: 2000-Quality Management System and the ISO 22000: 2005- Food Safety Management System. It also complies with the requirements of Occupational Health and Safety Management System - OHSAS: 18001. Presence - National & International “Paharpur 3P caters only to the organized sector of the Indian market,” says Anand. And how does the company define the unorganized sector? “Well, products like Pan Masala, Gutkha fall in that sector,” explains Anand. “The high ethical standards of our group restrict us from dealing in those products,” he adds. For Paharpur 3P, the buyers in the organized sector are major FMCG companies like Unilever, Nestle, Cadbury, Pepsi, Britannia, Heinz, HLL, ITC, Dabur, Mother Dairy, JK, MRF, SKF, Asian Paints, Heinz, Bayer, Tata Tea, Eveready, Parry, Britannia, Sara Lee, Novartis, Henkel, Perfetti and others. The company is in the premier category of manufacturers of Flexible Packaging and rated among the top five players in this field. The company has its marketing branches in Mumbai, Delhi, Bangalore, Kolkata, Chennai and Hyderabad. Paharpur 3P is present in SAARC countries, Middle East, Africa and Europe. As far as imports are concerned for the blown film plant, granules are imported from renowned suppliers like Dow, Exxon Mobil and Ampacet. Future Focus The future plans of Paharpur 3P include increasing the plant capacity from the present 7,000 MT to 12,000 MT per annum. That will also involve addition of new equipment at several stages of production. The company has been acquiring technologies from abroad as also equipment to meet its goal of moving up the profitable value added chain.
  11. 11. 11 The company has another unit in Chennai that caters to the needs of customers in the southern region like Hindustan Lever Ltd (HLL). On the technology front, the company has tied up with Perfotec of the Netherlands to provide competitive solutions for fresh produce. The company is working closely with technology leader in polymers, US-based Dow Chemicals and Toyo – a leader in food grade packaging inks. The Recognitions Paharpur 3P has always been recognized by its customers for its innovative ideas, product, quality, service and new developments. The company has several awards and recognitions to its credit like the Indiastar Awards, Asia star Awards, WordStar Awards, PFFCA Star Awards, Best HR Practices Award and the Eco-Friendly Company Award. Today 70% of products are manufactured for food applications where we are committed to provide safe and hygienic packaging for the food industry.
  12. 12. 12 Various departments in Paharpur 3P  Cylinder Preparation  Printing  Lamination  Slitting  Pouch Making  Blown Film  Quality control Department
  13. 13. 13 CylinderPreparation All gravure cylinders are produced on site using a dedicated fully automatic engraving and chroming line, which features two Max Daetwyler Gravostar 850 engraving heads. The GS 850 packaging engraver is a value-oriented unit, which includes a layout workstation, an engraver driver station and an engraver. It has a high frequency engraving head capable of engraving screens at up to 175 l/cm. As well as features such as telescopic enclosures, automatic lifting and lowering of the engraving head to prevent damage to the engraving head diamonds and on-board diagnostics the GS 850 also offers Daetwyler's Vista cell sensing system. The Vista system is used for head calibration and cell correction. Cells are measured on the fly, cell widths compared with the required widths and corrections made until the engraved cell is the right size. The system has a video monitor so that the user can see what the Vista camera sees and an optional printer that will output hard copy prints of the final cells for quality control purposes. Fully integrated, in-house, engraving facility to utilizing rotogravure cylinders .This gives an edge in replicating the designer’s idea flawlessly on the substrate, consistently, timely while ensuring utmost confidentiality. Machine use a diamond stylus to cut cells. Each cell creates one printing dot later in the process. They are fully computer-controlled and the whole process of cylinder-making is fully automated. Today Paharpur 3P have the capacity to engrave in excess of 9000 cylinder per annum. Web-fed gravure printing requires a gapless gravure cylinder, onto which the image is applied directly, by means of etching or engraving. For this, the cylinder must be prepared in a costly
  14. 14. 14 mechanical and galvanic process. In its basic design, the gravure cylinder consists of a thick- walled steel tube with flanged steel journals. To increase the stiffness of this hollow cylinder, some of the cylinder journals are drawn inwards and are supported inside the tube on additional steel discs. All of these joints are welded during the manufacture of the gravure cylinder so that a solid roller body is created, which still has to be balanced so that there are no vibrations when running at high speed (typically up to 15 m/s) in the printing press. The cylinder receives a base copper layer on its surface, which, among other things, serves to achieve the specified diameter of the finished gravure cylinder. For the application of another copper layer, which varies from print job to print job, there are several methods that are described in the following sections (note: the top copper layer is twice as hard (Vickers hardness approximately HV 200) as the base copper, so that this copper layer has good cutting properties as regards the electromechanical engraving process): The base copper layer is coated with an engravable copper layer (approximately 80 μm) in an electroplating process as shown in the figure above. This thin layer only allows a one-time engraving. The advantage of the thin layer technique is that all the gravure cylinders of one type have the same diameter dimensions and less mechanical surface treatment is required after the electroplating process than with thick layer processes (see below). The removal of the en-
  15. 15. 15 graving (after dechroming) is achieved by dressing or milling the copper. After this, a new copper layer is applied. (In the special process known as copper recycling, the copper layer is removed in an electroplating reversal process. In this process, an additional nickel barrier layer of approximately 25 μm between the base copper and engraving copper is necessary.) The thin layer technique is used in some 35% of cases, whereby the copper recycling method only accounts for some 5%. The process sequence for preparing an engraving cylinder is generally as follows: • removing the used gravure cylinder from the gravure printing press; • washing the gravure cylinder to remove residual ink; • removing the chrome layer; • removing the copper image-carrying layer, either chemically, by means of electroplating, or mechanically; • preparing the copper plating process (degreasing and deoxidizing, applying the barrier layer if the Ballard skin method was employed); • electroplating; • surface finishing with a high-speed rotary diamond milling head and/or with a burnishing stone or a polishing band; • Etching or engraving (producing the image on the gravure cylinder); • test printing (proof print); • correcting the cylinder, minus or plus (i.e., reducing or increasing the volume of cells); • preparing the chrome-plating process (degreasing and deoxidizing, preheating, and – if necessary – sometimes polishing); • Chrome-plating; • Surface-finishing with a fine burnishing stone or abrasive paper; • storing the finished cylinder or installing it directly in the gravure printing press. Electromechanical Engraving (As Done In Paharpur 3P)
  16. 16. 16 The operations involved in electromechanical engraving are significantly shorter compared to the etching process. Nowadays, they are normally controlled directly with the data recorded in prepress. In this way the mounting of a scanning original on a separate scanning drum that runs synchronously with the engraving machine is also no longer needed. Hence, the engraving machine only consists of a lathe-like device, into which the prepared gravure cylinder is mounted. The engraving procedure is similar to a rotating cutting process, but the cut is intermittent (stylus frequency). The gravure cylinder rotates during engraving at a constant surface speed (depending on the screen at approximately 1 m/s).At the same time the diamond stylus of the engraving head moves at a high frequency (4–8 kHz). The diamond penetrates the copper at different depths and produces the cell. The cells are equidistant from each other in the circumferential direction (direction of engraving) due to the continuous circumferential velocity and the engraving frequency. Engraving of neighboring tracks is semi-staggered. The lateral repeat length corresponds to the forward motion of the engraving head per cylinder revolution in the shaft direction of the gravure cylinder. Depending on the width of the web to be printed, up to sixteen engraving heads (typically eight) with styli are used for publication gravure printing. The burrs on the copper surface are usually removed by a scraper which is fixed to the engraving head during the engraving process. The cylinder must therefore only be lightly polished before it is used for a test print in a proofing press, corrected manually in accordance with this, and then finally chrome-plated.
  17. 17. 17 Printing Department Printing lines are equipped with the most modern facilities such as auto-registration controllers, viscosity controllers and are capable of in-line cold seal specialty coatings. Department Comprises of two High speed Machines. Rotogravure Press FR300 Shaanxi Beiren Printing Machinery Co., Ltd. Main Features 1. Double-working position disc-type Unwinder/Rewinder at high stable performance and the machine has the humanism design; new-type safe chuck assures the operators safety; unwinding cutter can complete up cutting or down cutting. 2. Indeed is at precise double-tension control. 3. Low-damping chill roller with good cooling effect prevents the web from being damaged at
  18. 18. 18 high- speed machine performance. 4. Centralized lubricant system at dosing greasing makes the guide roller high-speed and flexible performance. 5. Direct pressing mechanism makes the web performance without distortion, which can improve register accuracy and reduce the waste. 6. New-type environment protection and energy-saving drying system controls the residual impregnate efficiently. 7. Movable ink tray carriage shortens the auxiliary time and improves the productivity. 8. Straight-line cutter makes not only obverse/reverse cutting but also clearance-rewinding, and the rewinding reel is very tidy. 9. MMI touch screen and vector varispeed control system have the good performances Technical Parameters Max web width 520-1220 ㎜ Print speed 250m/min、300m/min Register accuracy ≤±0.10 ㎜ Unwind/rewind dia. Ф1000 ㎜ Plate cylinder diameter Ф420 ㎜-Ф940 ㎜ Drying method oil heating
  19. 19. 19 ROTOMEC ROTOPAK 3000 -3R Synthetic roller:- Synthetic Roller used for impression has hardness of about 65 to 75 shore. Number of colors 9 Web width (mm) 520-1220mm Print repeat range (mm) 400-920 Drying specifications 1-8 printing units double drying; 2 to 8 Single Drying . Drying heat source Oil Unwinder type Auto splicing Max reel diameter Unwinder (mm) 1000 Rewinder type Auto splicing Max reel diameter reminder (mm) 1000 Video camera Web video “Super Handy Scan 4000″ from BST (2011) Registercontrol Quadtech Viscosity control Eltromat Corona treatment Vetaphone treatment CP3/10kw
  20. 20. 20 Dent can also due to synthetic roller on the poly as in dent in the rubber or synthetic will come on different area on the poly but not side movement of that only up and down movement. As dent on gravure cylinder will occur at that same place and same position. • Defect can also occur due to oversized rubber roller in which ink from outside of gravure cylinder comes on that impression or rubber roller and then ink from that roller comes on the poly film which we are printing. • So always rubber roller of size equal to poly width and lesser than gravure cylinder length is used. • Misprint can also occur due imbalance of rubber roller as if a layer of ink keep on getting on that and in the end the thickness of that ink layer become more than the thickness of poly film we are printing so due to which rubber roller get imbalanced so at one end that roller is raised at one end due to which at some area we get print and at some not or lighten. • Diameter or circumference and length of the gravure cylinder are variable as according to the size of image along length or width we can say. • Here in Paharpur 3P gravure cylinder used are of same in length and circum but of different circum. • Both cylinder and blanket cylinder moves at equal speed. Here mainly electronic engraved cylinder with chromium plating is used. • Doctor blade :- • In this, it is made up of steel and is generally adjusted at an angle of 55 degree +- 5degree. • Thickness of the doctor blade is about 0.15mm. • Width of the doctor blade is about 45mm. • The adjustment of doctor blade is done by keeping the blade just sharp edge above supporter and pressing from one to other so that air filled between blade and supporter can be removed and then by holding both blade and supporter we tight down it. • Lamella: - It is the sharper edge of blade and its dimension is like this1.4/0.070mm here 1.4mm is length of that sharp edge and 0.070mm is thickness of that sharper edge. • DRYER: - This is the kind of system used for drying any applied chemical to polyfilm.
  21. 21. 21 Dryers’ temperature for printed matter is kept approximately 37 degree Celsius. For adhesive drying it is kept around74 to 76 degree Celsius. • Pre-make ready operations :- • Cleaning of the cylinder and blanket cylinder. • Centering of the gravure cylinder. • Web feeding and also tension control is done. • Doctor blade adjustment is also done. • Assembly plate is also adjusted according to the color gravure cylinder is in which unit placed.
  22. 22. 22 Lamination Department At Paharpur 3P -lamination facilities include:  Solvent based lamination  Solvent less lamination  Extrusion lamination  Water Based Lamination NORD MECCANICA - Super Simplex SL Technical Specifications Other Specifications Laminating materials BOPP 12-80 my PP CAST 20-150 my ALU 7-40 my LDPE-LLDPE 20-200 my Coex 25-200 my NYLON CAST 20-80 my Petp 8-30 my OPA 12-18 my PAPER 40-150 g/m2 Type of laminator: Solventless Working width: 1315 mm Unwinder diameter: 1000 mm Rewinder diameter: 1000 mm Mechanical speed: 400 m/min
  23. 23. 23 LAMINATOR NORDMECANICA-SUPER-COMBI 2000 Manufacturer NORDMECCANICA Model SUPER COMBI 2000 Year 2001 Application Duplex lamination Type of lamination/coating COMBI – SOLVENTLESS AND SOLVENT /WATER BASED Working width (mm) 1300 Speed 300 m/min First Unwinder type Single shaft less Max diameter reel Unwinder 1000 Secondary Unwinder type Single shaft less Max diameter reel Unwinder 1000 Rewinder type Single shaft less Max diameter reel 1000
  24. 24. 24 Rewinder Coating unit with interchangeable trolley; available 2 trolleys 1- Rotogravure trolley for solvent and water based glue 2- Solvent less trolley Drying 6M long drying tunnel; 2 independent hoods; 4 fans pumping mixing unit 2 components solvent less Coating rollers Approx. 15 rubber rolls Additional information 3 temperature regulation units; cold seal unit. In running conditions Laminated materials /secondary) Coatedmaterials (primary): BOPP 12–80µm; PETP 10–30µm; LDPE-LLDPE 60–20µm (solvent based); LDPE, LLDPE 30–200µm (solvent less); OPA 12–10µm; NYLON CAST 50–80µm (solvent based); NYLON CAST 30–80µm (solvent less); ALU 9–40µm (solvent based); ALU 12–40µm (solvent less); PP CAST 60–150µm; CALANDERED PAPER 40–300g/m2 (solvent less only). BOPP 12–80µm; PP CAST 20–150µm; ALU 7–40µm; LDPE, LLDPE 20–200µm; DIFFERENT COEXTRUDED MATERIALS 25–200µm; NYLON CAST 20–80µm; PETP 8–30µm; OPA 12–18µm; CALANDERED PAPER 40–300g/m2.
  25. 25. 25 Tandem Co-Extrusion Lamination coating Machine  Place of Origin: Guangdong, China (Mainland)  Brand Name: Huilong  Model Number: EXC  Voltage: 220v, 380v, 415v  Power (W): 220-300kw  Dimension (L*W*H): 23m*12m*5m Work Chart- 1. Unwind 2. Corona Treatment 3. Water Based Adhesive 4. 16micron Poly. (In Melted Form) + 10 Micron Matt applied via different rollers with applied Heat and Pressure. 5. Rewinding.
  26. 26. 26 Specifications ofMachine Extrusion Lamination Machine 1.EXC1350/ (90+90+90)-F-4 tandem co-extrusion 2. Thickness auto-control 3.Rewind auto-splicing Technical parameter: Product structure: laminating on single side 5 layers for one time: main materials/extrusion layer A/sandwich layer materials/co-extrusion layers B-C. Extruder: 3 sets HL-90 dynamic extruder, two of them formed into one HL-90S co-extrusion machine which use special-made extrusion laminating screw and feed block. Motor power is 37kw. Extrusion: maximum 200kg/h for single machine. Coating thickness: single layer T-die: 12-50μm; co-extrusion T-die: 12-60μm. (Single layer thickness is 6-50μm.) Production speed: maximum 150m/min. Specification: 1200mm,1350mm,1450mm,1700mm. Effective width: maximum 1100mm,1250mm,1350mm,1600mm. Base materials: BOPP, BOPET, BOPA, Paper (50-200g/). Sandwich materials: CPE, CPP, MCPP, MPET, Al-foil, Paper. Used resins: coating resin such as LDPE, LLDPE, PP, EVA, EAA, EMA, EMAA etc. Unwinder diameter: maximum 800mm or 1000mm. Rewinder diameter: maximum 800mm or 1000mm. Tension control: automatic tension control, maximum tension is 40kg. Electrical control mode: operated by MMI, extrusion thickness automatically controlled by computer, the whole machine is in linkage control state. Workshop requirement: Length 23m×Width 12m×Height 5m.
  27. 27. 27 Slitting Department SlittingDepartmentconsistsof 6High SpeedHi-Techmachines,whichare – NUZEN S-737 Mechanical Speed 450 Meter/Min** Max. Web width 1300 mm & up to 1600 mm* Max. Parent Reel Dia 1100 mm Parent Core I.D. 3” (76mm) & 6”(152mm) Combi chucks Max. Rewind Reel Dia 600 mm & Up to 800 mm* Max. Rewind Reel Weight 225 Kg.(Shaft) Min. Slit Width 50 mm Rewind Core I.D. 3”(76mm) & 6”(152mm)* Core Material Cardboard, Paper & PVC Max. Trim Width 5mm to 20 mm Web Guider Axial Motion +/- 50 mm / (+/- 100 mm)* Type of Slitting:  Razor Cutter (Cut in Air & Cut in Groove)*  Shear Cut (Rotary Knives)*
  28. 28. 28 MACHINES FEATURES: Unwind Section:  Shaft less unwind section  Combi chucks 3” (76mm) / 6” (152mm)  Ground Floor Pick up  Auto Self-centering  Automatic programmable tension control  Ultrasonic diameter sensor (for automatic diameter stop)  Digital Web Guiding System (Line/Edge/Contrast/Broken Lines)  Alignment roller  Guide/Idler rollers  Driven Bow (Banana) roller  Driven Unwinder*  Safety curtains at unwind* Tension Isolation Section:  Servo Driven Pull/Draw roller (for accurate Length Stop) (Length Counter)  ‘S-Wrap’ tension isolator Slitting Section:  Cantilevered designed shaft for quick and easy changeover  Razor Cutter (Cut in Air & Cut in Groove), Shear Cut (rotary cutter)*  Safety Guards for knives  Trimming removal/suction blower with Venturi Rewind Section:  Differential ball shaft technology  Automatic programmable tension control  Pneumatically controlled adjustable lay on (Linear Motion Technology)  Pneumatically controlled contact arms  Lay on Web clamp bar*  Programmable taper tension control  Servo Drive (for accurate Length Stop) (Length Counter)  Ultrasonic diameter sensor (for Automatic Diameter Stop)  Reel Ejector/Reel Removing System/Reel Thruster*  Pneumatic Swiveling type Take off arms (Reel Unloading Stand)  Safety Scanners at rewind*
  29. 29. 29 Star Slit Technical Data Star Slit Conslit General: Materials to be processed: Plastic films made from PE, PP, PA, PET, PVC, Paper, and Laminates, Working width: 57, 69" 40, 57, 69, 80" Machine speed: 2,000 fpm 2,600 fpm Drive side: on the right side, seen in material running direction Unwinder:
  30. 30. 30 Parent roll diameter: 40" 40" or 51" Options:  hydraulic roll lifting in device Slitting Section: Slitting width: starting from 2" (50 mm) (optional 1" (25 mm)) Slitting system: scissor cut, razor blade cut Rewind: Finished roll diameter: Max. 24" Max. 32" Finished roll cores: 3" and 6" I.D. (with corresponding accessories) Lay on rolls: full width contact rolls Winding tension: Max. 650 N Max. 650 N Options (depending on model):  Eccentric contact roll  Air expanding shafts  Auto push off for finished rolls  Laser core guides  Motorized roll tree  Close loop feedback  Auto or manual aid for shear knife positioning
  31. 31. 31 Titan ER610 compact slitter It is available in 2 web widths – 1350 & 1650 mm (53 & 65 INS) – with a maximum rewind diameter of 610 mm (24”). It also features a 10” touch screen control system and an integral edge-trim extraction system. The pneumatically controlled braking system provides accurate web tension control and a digital edge-guide system controls lateral movement of the unwind reel to +/- 50 mm (2”). Slitting systems available include shear knives, rotary razor (burst) or razor slitting in air or groove. Optional features include a static electricity control system, laser (line) core positioning, EU safety guarding, and laser safety scanners and unwind roll loading trolley. The Titan ER610 slitter will process a wide range of flexible materials including plain, printed, coated or metalized film from 20 to 200 micron, a wide range of laminates and paper from 30 to 200 Gsm
  32. 32. 32 DCM - Panthere 4 PANTHERE is a slitter-Rewinder well known to many converters all over the world. It is highly appreciated for its rewinding capacity of 800 mm diameters, its easy adjustment and the quality of its production. This is due to accurate tension control and cutting precision. EQUIPMENT : - Built-in or separate Unwinder - Unwinder with or without shaft - Razor and rotary cutter cutting station - Rewinding on air shafts or friction shafts - Digital Pilot touch screen control - Appropriate unloading system CHARACTERISTICS : - Width: 800 to 1600 mm - Diameter at Unwinder: 1000 or 1300 mm - Diameter at reminders: 2 x 800 mm - Minimum cut: 20 mm - Production speed: 600 m/min
  33. 33. 33 PouchingDepartment Pouching Department consists of 12 Pouch making machines of GALAXY PACKTECH IND. LTD. Of which 9 are “High Speed Bottom Fold & 3 Side SealPouch Making Machine” and 3 are “Automatic High Speed standup & zipper Pouch Making Machine (GS- 20)”. This department also includes two “Automatic Pouch SpoutInserter”. High Speed Bottom Fold & 3 Side Seal Pouch Making Machine  This model can make double up folded & three side seal pouch.  This model can make different length pouch on same time.  In built Cooling Technology provides leak proof product at high operating speed.  Pouch length variation minimized to zero by servo driven Laminate Pulling Mechanism.
  34. 34. 34 TechnicalSpecification Pouch Size Three Side Seal (W x L in mm) Folded Side Seal Pouch (W x L in mm) Min. 75 x 75 Min. 75 x 75 Max. 300 x 300 Max. 300 x 300 Linear Speed * 22 Mtr./Min. Roll Diameter Main Unwind (mm) Min. 125 Max. 600 Secondary Unwind (mm) Min. 125 Max. 600 Roll Width Main Unwind (mm) Max. 600 Secondary Unwind (mm) Max. 600 Elect. Power Consumption** Max 10 KW. 3 ph, 415 V (A.C.), 50 Hz. Prime Movers Servo Motor : 11 N-M / 2000 RPM Main Motor 3 Hp / 1440 RPM, 3 Ph. Air Consumption*** 8 CFM, 6 Bar Pressure (Water Contain less than 0.01%) Water Consumption 10-12 Ltr. / min., 8-12°C at 2 Bar Pressure. Operational speed depends upon Laminate Thickness, Composition and Pouch Size. Electrical Power Consumption depends upon application of machine. Air Consumption depends upon optional attachments.
  35. 35. 35 Automatic High Speed standup & zipper Pouch Making Machine (GS-20) ( Waterline) GS Series Advantage  The technology Ensures Excellent Pouch Seam even with High micron laminates.  In built Water Cooling Technology provides leak proof product at high operating speed.  Stand up pouches from same laminate roll provides competitive advantage to end user.  Pouch length variation minimized to Zero by servo driven Laminate Pulling Mechanism. Technical Specification Pouch Size Stand Up (W x L x G in mm) Three Side Seal (W x L in MM) Zip Pouch (W x L in MM) 1 Line Min 60 x 150 x 30 1 Line Min 150 x 160 1 Line Min 60 x 150 Max 500 x 500 Max 250 x 500 Max 250 x 500 x 100 2 Line Min 75 x 60 2 Line Min 60 x 75 Max 250 x 500 Max 250 x 250 2 Line Min 60 x 70 x 30 3 Line Min 50 x 60 3 Line Min 60 x 50
  36. 36. 36 Max 160x 500 Max 250 x 160 Max 250 x 150 x 100 4 Line Min 50 x 60 4 Line Min 60 x 50 Max 125 x 500 Max 250 x 125 Linear Speed * Upto 20 Mtr. / Min. Upto 22 Mtr. / Min. Upto 20 Mtr. / Min. Roll Width Main Unwind (mm) Bottom Unwind (mm) Min. 300 Min. 60 Max. 1000 Max. 200 Roll Diameter Main Unwind (mm) Bottom Unwind (mm) Max. 600 Max. 500 Optional Attachment Front & Back Eye mark Servo Synchronization Both Side Gusset Synchronization Same Roll Stand Up Pouch Former & Gusset Assembly D- Punch / Star Punch / Butterfly Punch etc. Secondary Film Roll unwinding Unit (1000mm) Elect. Power Consumption Max. 35 KW, 3 ph, 415 (A.C.), 50 Hz Prime Power Servo motor: 26 N-M / 2000- RPM Main motor 5 Hp / 1440 RPM, 3 Ph. Unwind Motor (4 Nos.) 1 HP, 1440 RPM 220V AC , each 3 Ph. Air Consumption 8 CFM, 6 Bar Pressure (Water Contain less than 0.01 %) Water Consumption 10 – 15 Ltr. / Min. 8-12 C at 2 Bar Pressure. Operational Speed depends upon Laminate Thickness, Composition and Pouch Size Electrical Power Consumption depends upon application of machine Air Consumption depends upon optional attachments
  37. 37. 37 Name: NCA1620-30 Automatic Pouch Spout Inserter Model NCA1620-30 Pouch size L×W(120-320)×(100-250)mm MAX: 300×250mm 320×200mm Cutting angle 17°-45° Spout type Short spout Capacity 30-35pieces/min Power AC 380V, 50HZ, 3P, 4.0KW Compressed air 0.5Mpa 250NL/min Cooling water 6L/min Dimension L×W×H 35000×1800×1950mm Weight 1800Kg Main Technique Features: ● Angle of the spout-welding can be adjusted from 17°to 45°, the angle-cutting and the spout- welding can be done at the same time. ● Max size of pouch can be 2200ml. (Special order is needed for the over size) ● Clear display, PLC control, easy operation. ● Double servo pouch supply guarantees the accurate position. ● Spout preheat and reduce the hot sealing temperature. ● Multi-hot sealing, cold sealing, ensure the sealing strength. ● Trouble alarm display.
  38. 38. 38 QUALITY CONTROL DEPARTMENT • TENSILE STRENGTH MACHINE - There are three types of tests are done that are:- Sealstrength  First of all in this strip of poly or substrate of about 1.5cmor 15mm in width we cut down.  After this we fold that strip along the length wise.  Than we seal folded mouth or end of that strip with pressure heating machine and we get sealed strip.  Now we put that strip with open mouth or end upper end of it in upper mouth and then another end in the down holding mouth.  In the end we start the machine in which downward mouth will towards down till that we seal breaks we note down the reading.  In this way we get seal strength and we can change according to that. OperatingRange- NS40 to IT 500.  Pneumatic operated cylinders with individualsolenoidvalve.  Specially designed heaters & reputed electrical system.  Machine working capacity- approx. 300 batteriesper8 hourshift.  Electricity Required- 7 KW, 3 Phases, and 415 V- AC,@ 50 Hz.  Machine Weight- app. 700 kg., Size- 5’L X 6’ b X 7’ h  AirRequired- 3-4c.f.m.@ 7kg/cm2  Operating temperature range is 350o c to 38Oo c
  39. 39. 39 Tensile strength or Elongation strength:- We have to measure the elongation or tensile strength along machine direction as well as cross direction  In this type we measure the elongation strength or stretch till poly or substrate breaks.  First of all we take a strip of width 2.5 cm or 25 mm and 10 cm or 100 mm in length  After that fixing it into both ends of the machine and then stretched until it breaks and in this we note down the distance and load it can acquire or tolerate  The unit of both the test is calculated in manpower means force/area.  We also measure the adhesive strength of the poly films we use to adhere with each other.  This is done by splitting both layers of poly films. Drop test or Dart impart test - it is also known as bursting strength.  In this test we measure out that how much pressure or load it can hold if any substance poly pouch gets dropped from certain height.  First of all the substrate is tightened on hollow cylinder with some air pressure and then after tightening again pressure of about 490mm Hg is applied to hold it tightly.  Than pendulum of some weight is set at the height of 66 cm and dropped from there.  We check it out whether the poly gets burst or not.
  40. 40. 40 GSM and micron measuring machine "LINUX" GSM TESTER - Electronic Model The equipment is designed to measure/determine GSM of Paper, paperboard, fabric, PVC, plastic and other materials. It measures 5 different sample sizes viz., 5x5cm, 10x10cm, 10x20cm, 20x20cm and 25x25cm. It displays Gsm of samples cut selected to size on a digital indicator. Has printer port facility for printing and data transfer. The equipment comprises of an electronic scale of 125 Gsm capacities and least count of 0.01 gm and templates. Two templates are supplied with the equipment and other sizes are available on request. There are two types of polyfilm are measured:- • Printed • Non printed • Printed poly film:- First of all we cut out the sample • For printed poly films, first of all we measure the GSM of the printed substrate or poly film sample. • Then we split out coated film and remove the ink from printed substrate or poly film with ethyl acetate or toluene properly.
  41. 41. 41 • After that we measure the GSM of both the film and then we find out the difference of both the poly films (printed and cleaned). • In the end we can measure out that GSM of the ink layer on the sample. We can also measure the adhesive layer applied between poly films which are laminated by same way as for printed we does. Non printed polyfilm:- • We cut out the poly film or substrate of size about 10*20cm and then we measure out the GSM of that piece. • Than we divide that value by 2. • After that we multiply it with 100. • In this way we measure out the GSM of the substrate and we can know uniformity of poly films. WE CAN ALSO MEASURE MICRON OR THICKNESS OF THE POLYFILM BY DIVIDING THE GSM OF THE POLYFILM BY DENSITY OF THAT POLYFIM ONLY. MICRON = GSM / DENSITY • For poly tube type poly film we measure just GSM simply along width 20 cm. • For different poly films we measure GSM separately along the width to cover the whole poly. • GSM unit is in gm • 38 to 42 dyne charge is given on the polyfilm through corona discharge method. Friction testermachine:- • In this we measure both static and dynamic friction of poly films. • In this we just keep the wide strip of poly with treated side up and then we keep some solid slab on it. • Than that solid slab is moved on that strip.
  42. 42. 42 • Reading which comes on that meter we note it down. • The purpose of the friction testing is check whether more or less force to be applied to move the poly film to be printed for e.g. if there is more friction in the poly then it will not move to required or vary speed so in this way it will not properly printed or laminated or slitted or if coefficient of friction is less than required it will not be controlled over the rollers as it will slide more than required. • Treated and non treated both side are checked as treated side is checked so that when we keep each poly on each other should not slip for e.g. lamination needed two layers on each other and to cut it properly so that it moves under rollers properly, non treated side is checked for filling material in it. • Here only we take dynamic friction of more concerned as in printing movable is there more important rather than static friction we don’t take so much. • Its unit is in Newton/meter *meter. Opacity testing machine:- This is the machine used for measuring the amount of light is getting transmitted through poly film. • In this, we take a strip of poly and put in frame and then light is passed, then we note the percentage of opacity. • In this it is measured in percentage. Treatment test:- In this test, we check out which is the treated side, meaning on which side of poly film we had increased the surface energy or charge. • We take strip of adhesive tape and adhere to both the side of poly and pluck off then. • And on which side it makes less noise than it is treated side.
  43. 43. 43 Puncture Resistance Tester The Puncture Resistance Tester is used for determining the puncture resistance of corrugated board by measuring the energy required to puncture it. Interchangeable weights supplied to cover four energy ranges i.e. in new meter 0-5, 0-10, 0-20 & 0-36. Applications  Testingequipment  Paperindustry  Packagingindustries. Electronic Box Compression Tester It has single push button operation which activates an automatic test cycle, machine starts in fast speed, detects the box, changes to standard test speed & performs compression test. Overload protection. Acceptable and non acceptable limit set.
  44. 44. 44 Applications  Testingequipment  Paperindustry  Packagingindustries Universal Oven  forced air circulation by quiet air turbine, adjustable in 10 % steps  adjustment of pre-heated fresh air admixture by air flap control in 10 % steps  vent connection with restrictor flap  adaptive multifunctional digital PID- microprocessor controller with high- definition TFT-color display  self-diagnostics for fault analysis  1 Pt100 sensor DIN class A in 4- wire-circuit
  45. 45. 45 RAW MATERIALS USED EXTENSIVELY IN PAHARPUR 3P INKS As we knowthatany packagingthat isnot hard and bendsslightlywhile still holdingashape.Itcan be a bag, envelope orpouchthatwhenfilledchangesshape.Liquidinksusedforprintingof these flexible packageswithGravure Process,CalledFlexiblePackagingLiquidInks. High quality inks of various prestigious companies like ”Sakata” and “DIC” are used In Paharpur 3P LightFastness Rub Ink Properties Rub Scuff H2O2 Heat /Freeze
  46. 46. 46 Types of Inks, Their Uses and Properties. Vinyl Based Benefits:  High color strength  Good bond strengths  Almost instant adhesion  Low solvent retention  Reliable, high performance results  Free from migrating plasticizer resins. Use:- High Mileage Jobs. PU Based Benefits:  High color strength  Low solvent retention  Prints on wide range of plastic films  Reliable, high performance results  Does not contain pigments based on heavy metals. Use:- Used in All Types Of Jobs. Acrylic Based Acrylic Inks are optimally pigmented and low viscosity inks, for Gravure Printing, high quality reverse printing applications – directed at Shrink PVC film applications. Special Features:  Optimal strength
  47. 47. 47  High HR properties  Good Printing Stability  Good Blocking resistance  Excellent adhesion on PVC films  Good scuff resistance & slip properties Polyamide Based Inks are highly pigmented inks, for high quality Surface printing Special Features:  Good Printing Stability  High gloss  Good Blocking resistance  Excellent adhesion on various filmic substrates  Good scuff resistance & slip properties Use:- Used for High Quality Surface Printing NC based TRUMET FOIL Inks are for Gravure Printing Special Features:  Excellent adhesion  Excellent HR  Low odor  Good scuff resistance & slip properties Use:- Mostly used in Food Packaging
  48. 48. 48 Substrates • Polyester (pet) or polyethylene terephthalate:- BoPET (Biaxially-oriented polyethylene terephthalate), known in the industry as polyester (PET) is a versatile film used in many flexible packaging applications including lamination. Available in either corona or chemically treated options for print and conversion. Melior Film Converters also offer a heat sealable PET film for flow wrap or lidding film applications. The properties that make PET film ideal for packaging applications include:  High strength for high speed processes, higher tensions, and higher temperatures  Chemical surface treatment during manufacturing or post-manufacturing to enhance characteristics, such as barrier, adhesion, printability, metal adhesion, and release  High clarity Strength and resistance to tear  Dimensional stability over a very wide range of temperatures and humidity  Resistance to attack by moisture and most common solvents  Excellent barrier to both oxygen and water vapor to extend shelf- life  It is a condensation polymer  Its density is about 1.40.  Its thickness is from 12micron to 15 micron.  Its temperature after printing for drying is 60degree to 70degree.  Only reverse printing can be done on the polyester. Types of Polyester used in Paharpur and their Applications. Type Of PET Application Corona Treated Normal Bond Jobs Chemically Coated High Bond Acrylic Oil Jobs Alox High Stanlization Jobs Max Barrear High Retort ( Stanlization Jobs )
  49. 49. 49 Biaxially oriented polypropylene (BOPP) When polypropylene film is extruded and stretched in both the machine direction and across machine direction it is called biaxially oriented polypropylene. Biaxial orientation increases strength and clarity.[13] BOPP is widely used as a packaging material for packaging products such as snack foods, fresh produce and confectionery. It is easy to coat, print and laminate to give the required appearance and properties for use as a packaging material. This process is normally called converting. It is normally produced in large rolls which are slit on slitting machines into smaller rolls for use on packaging machines. Mostly used in Packaging of Biscuits, Snacks and chips. White BOPP  For food and confectionery packaging  Suitable for single ply or lamination applications  Suitable for VFFS and HFFS packaging applications  Both sides heat sealable  One side (external) corona treated for conversion  Excellent ink adhesion for flexographic and rotogravure process  High whiteness and gloss Used in Product Labels. BON Biaxially Oriented Nylon Biaxially Oriented Nylon film, also known as BOPA film, is made of polyamide resin, which can be used for a wide range of applications especially where high barrier requirements to gas,fat and transmission of aroma are necessary. High resistance to impact punctures and pin holing. Mostly used in OIL jobs like Sundrop due to Puncture Resistance.
  50. 50. 50 Polyethylene Polyethylene is the most produced plastic in the world, with which everyone daily comes into contact. Polyethylene can be processed into soft and flexible as well as into tough, hard and strong products. It can be found in articles of all kind of dimensions, from the simplest to the most complex shapes. It is used in everyday appliances, packaging, pipes and toys. Three main types By making polyethylene more or less "dense” in the factory, there is a suitable type of material available for every application. In practice one of the following types is used in 90% of the applications. LDPE: "low density” polyethylene the oldest type. A soft, tough and flexible polyethylene type, used for strong, flexible consumer items, like screw caps and lids. For a long time already, it is also used as insulation material. At present the most popular application is foil, from which carrier bags, packaging material and agricultural plastic are made. During the high water levels in Holland in the last years, the tough strong LDPE foil served as an improvised reinforcement for the dikes. HDPE: "high density” polyethylene this is the sturdiest and most inflexible type. Its sturdy and somewhat tough character can be used for a large range of applications. For example the well-known gft-container and a number of everyday domestic products like bottles, clothes pegs and the handle of washing-up brush. Although HDPE is quite heavy, it can also be used for paper-thin foil that is extremely light and feels crispy. All of us use this type of foil daily; examples are sandwich bags, pedal bin bags or packaging for vegetables, fruit or meats. LLDPE: a mixture of both previous-mentioned types with this polyethylene one can go into every direction. It has some features from both of the previous-mentioned types. Both flexible and sturdy products are made from it. LLDPE is generally used in mixtures with one of the previously mentioned materials. Amongst others, even thinner foils can be produced. It is also used for multi-layer packaging. LLDPE is extremely tough and inflexible. These features can be used for the production of larger items, like covers, storage bins and some types of containers.
  51. 51. 51 Solvents Used Ethyl acetate  Its density is 0.89.  It is used as solvent to maintain the viscosity of the ink.  It is also used to clean the printed ink from poly in quality dept. to check the GSM of printed poly.  It is used in reverse printing. Toluene  density is about 0.87.  It is used to maintain viscosity.  It is used for surface printing. Methyl Isobutyl Ketone (MIBK) Physical Properties Molecular weight 100.16 Boiling point 117.4°C Vapor pressure 16 Torr at 20°C Freezing point -84°C Isopropyl Alcohol (IPA) Molecular weight 60.09 Boiling point 82.26°C Vapor pressure 32.4 Torr at 20°C
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