Project Report On Flexo Printing Manufacturing Facility
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EIRI Board of Consultants and PublishersProject Report On Flexo Printing Manufacturing Facility
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EIRI Board of Consultants and PublishersFLEXO PRINTING MANUFACTURING FACILITY
[EIRI/EDPR/3901] J.C.: 2019
INTRODUCTION
Flexible packaging refers to any package or part of a package the shape of which can be
readily changed. Flexible packaging includes, but is not limited to, bags, pouches,
liners, and wraps utilizing paper, plastic, film, aluminum foil, metalized or coated paper
or film, or any combination of these materials. Flexible package manufacturers are
sometimes referred to as "converters." The word "converted" in this use is an industry-
specific term that refers to the fact that flexible packaging materials start out as rolls of
paper or foil, or beads of plastic resin, and are "converted" into a package or roll of
packaging material.
Flexography is a roll-feed web printing process. Flexographic printing is commonly used
to print high volumes of labels and packaging. Presses can print on a variety of films,
foils, papers, corrugated board, and paperboard and achieve speeds of 500 to 2000 feet
per minute.
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In the simplest and most common form, the flexo process consists of below mentioned
components 1) Fountain pan / tray , 2) Fountain roll, 3) Doctor blade , 4) ink-metering (
anilox ) roll , 5) plate cylinder and impression cylinder, 6) Impression roll , 7) Substrate
These are illustrated in the figure below. 4/17/2018 13 In the simplest and most
common form, the flexo process consists of below mentioned components 1) Fountain
pan / tray , 2) Fountain roll, 3) Doctor blade , 4) ink-metering ( anilox ) roll , 5) plate
cylinder and impression cylinder, 6) Impression roll , 7) Substrate.
Products printed on flexo presses include adhesive and shrink-sleeve labels (bottle
wraps); ice cream cartons; folding cartons; shopping bags; plastic bags; pouches;
packets; gift wrap; tissue; envelopes; wallpaper; and disposable plates and cups.
Printing on flexible packaging is almost entirely conducted by rotogravure and wide- web
flexographic printing. The ratio of rotogravure printing to flexographic printing among
converters is approximately 1:4. Flexible packaging printers are likely to be included
under SIC codes 2671, 2673, 2674, and 3497. Typical NAICS codes for this industry
include 322221, 326112, 322223, 326111, 322224, 322225, and 332999. Flexible
package printers could also be classified under other SIC and NAICS codes as well
depending on other processes conducted at the facility.
Printing, coating, and laminating may all be performed on or in-line with a flexible
package printing press and these activities are included in the source category. One
portion of the flexible packaging industry provides fully printed packaging materials
(designated "preformed specialty bags") to contract packagers. Another portion provides
combination or laminated materials (designated converted wrap) for printing and/or
final packing by captive packaging operations. Applying coatings is a major capability of
flexible packaging converters, so the same facilities may be used to manufacture non-
packaging materials such as gift wraps and hot stamp foils. The industry makes a
distinction between labels and wrappers, which are package components, from a
product that becomes the entire package and should be called a flexible package. Any
printing of shrink-wrap labels or wrappers conducted on or in-line with a flexible
package printing press is also considered to be included under the flexible packaging
source category. Printing of self-adhesive labels would not be considered flexible
packaging.
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Rigid packaging printing operations are often times co-located with flexible package
printing operations. Folding cartons, some labels and wrappers, gift wraps, wall
coverings, vinyl products, decorative laminates, floor coverings, tissue products, and
miscellaneous specialty products are not considered flexible packaging.
UV flexo technology is quickly establishing itself as a bridge to sustainability within the
graphic arts markets. Historically, energy-curable systems were used in surface printing
applications (PSA labels, shrink sleeves, in-mold, food packaging, etc.) where the
properties of cured UV inks and coatings led to improvements in abrasion resistance
compared to solvent- andwater-based inks. It was also found that UV inks performed
well with UV and EB coatings used in flexible packaging structures. Currently, UV flexo
inks are being applied on the internal and external surfaces of a broad range of high
performance packaging structures. In addition, UV flexo inks provide a significant step
toward sustainability by eliminating/reducing the emissions of VOCs and CO2.Generally
speaking, the drying of a conventional ink film occurs when the ink solids(resins,
additives, pigment, etc.) coalesce into a film on the substrate surface accompanied by
evaporation of volatiles and/or penetration into the base substrate. In some cases,
conventional inks require several hours for complete drying. With energy-cured
materials, the majority of the components in the ink or coating remains on the surface of
the substrate and are chemicallyconverted within seconds to a hard surface “film”
following exposure to UV or EB energy. The difference between these processes lies in
the chemistry of the materials in the inks and coatings,and in the technology required to
energize the curing process.
The formulation of UV flexo inks with low viscosity, high color strength, high cure
speeds and adhesion is a considerable challenge for ink formulators. The rheology of UV
flexoinks is significantly improved with measured combinations of resins, additives and
pigment wetting vehicles. Oligomers are the primary resins in an energy-cured ink and
provide basic ink properties, while monomers are used primarily for viscosity reduction.
Relative to optimizing anchorage of these oligomer-monomer carriers to the substrate,
surface modification by corona, flame or atmospheric plasma all have potential to do so
because of their efficient surface roughening and functionalizing effects. This
collaborative study was undertaken to understand the potential synergistic interactions
between different atmospheric pressure surface modification techniques and different
oligomer types in UV flexo ink formulations, and the overall impact of these synergies on
ink adhesion to various unprimed, flexible polymer-based surfaces.
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CONTENTS
INTRODUCTION
HISTORY OF FLEXOGRAPHIC PRINTING
CLEAR PACKAGING
TYPES OF PRINTING PROCESSES
OFFSET LITHOGRAPHY
ROTOGRAVURE PRINTING
FLEXOGRAPHIC PRINTING
TYPES OF PRINTING INKS
TYPES OF FLEXOGRAPHIC INKS
CHOICE OF SUBSTRATE IS ALSO ONE OF THE MAIN FACTORS IN INK SELECTION.
SUBSTRATES CAN INCLUDE:
4 COMMON TYPES OF FLEXOGRAPHIC INKS
HERE ARE SOME MORE DETAILS ON THESE TYPES OF INKS, AND WHAT
APPLICATIONS
THEY'RE BEST FOR:
1. WATER BASED
2. SOLVENT BASED
3. ULTRAVIOLET (UV) AND ELECTRON BEAM (EB)
4. OIL BASED
FLEXOGRAPHIC INKS ARE SEPARATED INTO TWO CLASSIFICATIONS: VOLATILE
AND ENERGY CURABLE.
THE UNCOATED FILMS USED FOR UV BASED INK-
FLEXOGRAPHIC INK FOR POLYETHYLENE FILM
UV INK
HOW FLEXO PRINTING WORKS
THE STEPS FOR PREPARING PHOTOPOLYMER PLATES ARE
INKS
SUBSTRATES
FLEXOGRAPHIC INK DELIVERY SYSTEM
PRESS CONFIGURATIONS
COMMON IMPRESSION CYLINDER (CIC) PRESS
STACK PRESS
CORRUGATED PRESS
REPEAT LENGTH
PLATE TYPES
MOLDED RUBBER
PHOTOPOLYMER
LASER ABLATED PLATES
PLATE ELONGATION
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DISTORTION
TYPE WEIGHT
DOT GAIN IN FLEXOGRAPHY
PLATE DUROMETER
INKS
WATER-BASE INK
SUBSTRATES
CHEMISTRY OF UV (PHOTOINDUCED) CURING TECHNOLOGY
THE MAIN COMPONENTS OF SUCH FORMULATIONS BASED ON RADICAL
POLYMERIZATIONS ARE:
PROPAGATION
TERMINATION
USES AND APPLICATION
MARKET CATEGORIES
CORRUGATED
FLEXIBLE PACKAGING
GIFT WRAP AND WALLPAPER
FOLDING CARTONS
RIGID PAPER BOXES
ENVELOPES
PAPER GROCERY BAGS
PLASTIC CARRIER BAGS
MILK CARTONS
TAGS AND LABELS
PRE-PRINTED LINERBOARD
APPLICATION AREAS OF UV CURING INKS
PROPERTIES OF MACHINE
ADAVANTAGE & DISADVANTAGE
ADVANTAGE:-
BENEFIT: HIGHLY AUTOMATED
BENEFIT: COST EFFICIENT
BENEFIT: FAST
DISADVANTAGE:-
DRAWBACK: NOT IDEAL FOR SMALLER JOBS
DRAWBACK: SETUP CAN BE TIME CONSUMING
MARKET SURVEY
KEY PLAYERS
FLEXOGRAPHIC PRINTING INKS MARKET, BY APPLICATION
FLEXOGRAPHIC PRINTING INKS MARKET, BY REGION
COMPETITIVE MARKET SHARE
MACHINERY SUPPLIERS
RAW MATERIAL SUPPLIERS
INK
SUBSTRATE
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MACHINERY PHOTOGRAPHS
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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COST ESTIMATION
Plant Capacity 5,00,000 Pcs/Day
Land & Building (600 sq.mt.) US$ 92 Th.
Plant & Machinery US$ 5.85 Lac
Working Capital for 1 Month US$ 10.01 Lac
Total Capital Investment US$ 17.48 Lac
Rate of Return 64%
Break Even Point 26%
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