This document provides information about printing and lamination processes at Packages Limited. It discusses two main printing techniques used: flexography and gravure printing. For flexography, it describes the flexographic printing process and components involved. For gravure printing, it outlines the rotogravure process. It also covers wet bond and dry bond lamination processes and the materials that can be laminated. Finally, it discusses common materials used for flexible packaging films like PET, PP, PS, PVC, HDPE, LDPE, BOPP, and nylon films along with their properties.

1. Printing, Lamination & Material
Structure
Muhammad Zubair Qadir
Intern Engineer (Flexible Packaging)
(01/06/2018 - 13/07/2018)
UET LHR (KSK Campus)

2. Printing Section

3. Printing is a process for reproducing text
and images using a master form or template.
Packages Limited is using two types of printing techniques at
the moment.
I. Gravure printing OR Rotography
II. Flexography
Printing

4.  Flexography
A rotary relief printing
method using rubber or plastic
plates and fluid inks or dyes
for printing on fabrics and
impervious materials such as
plastics, as well as on paper.
Types of Printing

5. Cont…
A photopolymer or light-activated
resin is a polymer that changes
its properties when exposed to
light, often in the ultraviolet or
visible region of the electromagnetic
spectrum.

6.  Gravure printing
Rotogravure (roto or gravure
for short) is a type of intaglio
printing process, which involves
engraving the image onto an
image carrier.
Cont…

7.  Flexographic Machine
Layout

8.  Gravure Machine
Cont…

9. Flexographic Processing
 The first step in the flexographic printing process is to
develop the image and text that is going to be printed.
 Once the design has been created, plates need to be
molded or engraved to reflect the designs that are to be
printed. For each color that needs to be printed, a unique
plate is created. Once the plates have been made, the
printing process is ready to begin.
Processing

10.  For the most part all flexos work using the same broad
method using a series of three rollers.
 The first roller applies the ink, the second has the plate
attached, and the third is an impression roller.
 The first roller is programmed to disperse a predetermined
measurement of ink to the plate.
 Then, the material being printed on is passed between the
print plate and the impression roller, which applies pressure
to the keep the material firmly against the plate to create the
highest quality of final product.
Cont…

11. Rotogravure Processing
 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.
Cont…

12.  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.
Cont…

13. Comparison

14. Lamination Section

15. A Laminating is the process through which two or
more flexible packaging webs are joined together using a
bonding agent. The substrates may consist of films, papers
or aluminum foils.
Usually there are two types of lamination processes used in
industry.
 Wet Bond lamination
 Dry Bond lamination
Lamination

16. Wet Bond lamination
 A laminating process used to laminate two substrates, one of
which is porous, such as paper. For example, a foil and paper
substrate lamination may be accomplished through a wet
bonding process.
 Once the wet bonding process is applied to each substrate, the
two substrates will then be combined prior to passing through
an oven, which is used for the drying process.
 This drying process is where the adhesive materials will dry,
essentially adhering the two substrates together, therefore, the
two substrates need to be combined before the adhesive is
dried in the oven.
Laminating Processes

17. Dry Bond lamination
 A laminating process used to laminate two substrates, both of
which are non-porous, or impervious to filtration. For
example, film on film, and film on foil laminations would go
through the process of dry bonding.
 The adhesive used to combine the two substrates together will
be applied to either one of the substrates, and then dried in an
oven prior to being combined with the second substrate.
 The two substrates are combined after the adhesive is dried
for maximum efficiency of the dry bond lamination process.
Cont…

18. 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.
Cont…

19.  Wet Bond lamination
Layout

20.  Dry Bond lamination
Cont…

21. Adhesive Comparison

22. Problems

23. Lamination Materials

24.  A critical part of the flexible packaging process is selecting
the proper type of packaging material for your product.
 General Laminated Film is made of multiple raw material
layers with barrier properties that are chosen depending on
the customer’s needs.
 With its increased efficiency, General Laminated Film is
widely used in high speed production for flexible packaging
because of its advantages for quickly packaging as it
increases efficiency.
Introduction

25. Material Types

26. Cont…

27. Properties
Poly Ethylene Terephthalate (PET)
 PET film is mostly found in nonfood, non-packaging
applications, such as photographic film, x-ray film and
magnetic audio and video recording film.
 Its primary packaging uses, however, are in metallized
packages, such as those for potato chips and pretzels, as well
as in microwave packaging, brick packs and medical
packaging
 It also can be found in tobacco wrap, cigarette wrap and labels.
 PET is used in these and other applications because it has good
mechanical properties such as toughness and stiffness and
good thermal properties.

28. Polypropylene (PP)
 PP has good chemical resistance, is strong, and has a high
melting point making it good for hot-fill liquids. This resin is
found in flexible and rigid packaging, fibers, and large
molded parts for automotive and consumer products.
 Excellent optical clarity in biaxial oriented films and stretch
blow molded containers
 Low moisture vapor transmission
 Inertness toward acids, alkalis and most solvents
 Containers for yogurt, margarine, takeout meals, and deli
foods. Medicine bottles. Bottle caps and closures. Bottles for
catsup and syrup.
Cont…

29. Polystyrene (PS)
 PS is a versatile plastic that can be rigid or foamed. General
purpose polystyrene is clear, hard and brittle. It has a
relatively low melting point.
 Typical applications include protective packaging,
foodservice packaging, bottles, and food containers.
 PS is often combined with rubber to make high impact
polystyrene (HIPS) which is used for packaging and durable
applications requiring toughness, but not clarity.
 Excellent moisture barrier for short shelf life products
 Significant stiffness in both foamed and rigid forms
 Low density and high stiffness in foamed applications
 Low thermal conductivity and excellent insulation properties
Cont…

30. Polyvinyl Chloride (PVC, Vinyl)
 In addition to its stable physical properties, PVC has good chemical
resistance, weather-ability, flow characteristics and stable electrical
properties.
 High impact strength, brilliant clarity, excellent processing
performance
 Resistance to grease, oil and chemicals
 Rigid packaging applications include blister packs and clamshells.
Flexible packaging uses include bags for bedding and medical,
shrink wrap, deli and meet wrap and tamper resistance.
Cont…

31. High Density Polyethylene (HDPE)
 HDPE is the most widely used type of plastic. It’s used to
make many types of bottles and containers..
 Because HDPE has good chemical resistance, it is used for
packaging many household and industrial chemicals such as
detergents and bleach.
 Excellent resistance to most solvents
 Higher tensile strength compared to other forms of
polyethylene
 Relatively stiff material with useful temperature capabilities
 Bottles for milk, water, juice, cosmetics, shampoo, dish and
laundry detergents, and household cleaners. Bags for
groceries and retail purchases. Cereal box liners.
Cont…

32. Low Density Polyethylene (LDPE)/(LLDPE)
 LDPE is used predominately in film applications due to its
toughness, flexibility and relative transparency, making it popular
for use in applications where heat sealing is necessary.
 LDPE also is used to manufacture some flexible lids and bottles as
well as in wire and cable applications.
 Excellent resistance to acids, bases and vegetable oils
 Toughness, flexibility and relative transparency (good combination
of properties for packaging applications requiring heat-sealing)
 Bags for dry cleaning, newspapers, bread, frozen foods, fresh
produce, and household garbage. Shrink wrap and stretch film.
Coatings for paper milk cartons and hot and cold beverage cups.
Container lids. Squeezable bottles (e.g., honey and mustard).
Cont…

33. Bi-Oriented Poly-Propylene (BOPP)
 OPP & BOPP are the same type of films
 Film is stretched in both the machine and transverse direction
after it is extruded
 This increases the films stiffness clarity & tensile strength
 It is used for the wrapping of hard candies and chocolates
 Resistant to heat and moisture
 Shiny, high gloss appearance
 When laminated with metal foil (MET), it increases the film’s
oxygen & water barrier. It also block out UV rays
Cont…

34. Nylon Films
 Since they have high melting point, they are used for cooking
applications such as microwave and baking
 Very good clarity and moisture barrier
 Considered as very strong film
Cont…

35. Laminated Aluminum Foil Bags
 Laminated foil roll is resistant to water and a number of
chemical components. Opaque, the adhesive foil lamination
process is ideal for foils employed to protect sensitive
materials from light
 Laminated aluminum foil film and bags have great seal
abilities, and good chemical and water resistance
 Its advantages are excellent as they are opaque, with good
oxygen barrier, well formed, and maintain fresh the content
with long-term preservation.
 Laminated aluminum bag and rolls can be used on pizza
wraps, beverage packaging, tablet packaging, coffee bags and
snack food packaging, as well as cosmetic, facial mask, bio
medical packaging, anti-static semiconductor packaging etc.
Cont…

36. Comparison

39. THANK YOU