Rollatainers Report

8/17/2019 Rollatainers Report

1/33

1

ECHELON INSTITUTE OF TECHNOLOGY DEPARTMENT OF MANAGEMENT

A

PROJECT REPORT

ON

TRAINING AND DEVELOPMENT

IN

Submitted to Echelon institute o technolo!"

In the partial fulfillment of the requirement for the summer training report

Submitted by:

GUDDU KUMAR

1!M"!1#

$RA%&'! M"!$ ()th semester*

DEPARTMENT OF MANAGEMENT

ECHELON INSTITUTE OF TECHNOLOGY

FARIDA#AD


2/33

2

INDUSTRIAL TRAINING REPORT

ROLLATAINERS LIMITED

PLOT NO. 14/5,Mathura Delhi Road

DISTT: arida!ad "#AR$ANA %

Pi& 'ode: 121((1


3/33

)

CONTENTS

1) Acknowledgement

2) About

3) Service

4) Mission

5) Quality Policies

) !e"artments

i# Pre Press

ii# Press

iii# Post Press

iv# Quality $ontrol

%) &ravure Printing Section

A$'(*+,!&,M,(- .


4/33

4

It i* a +lea*ure to re'eie to u+hold - +ra'ti'al a* ell a*

theoreti'al *0ill* i& +ri&ti& te'h&olo. The *+e'ial tha&0 oe*

to - hel+ul Produ'tio& Ma&aer, Mr. Dee&der Ra&a a&d Di&e*h

Shar-a. The *u+eri*io& a&d *u++ort that he ae trul hel+ the+rore**io& a&d *-ooth&e** o the i&ter&*hi+ "Su--er I&du*trial

Trai&i&% +rora-.

M tha&0* o to Mr. Dia0ar $ada. A !i 'o&tri!utio& a&d

hard or0ed ro- ou duri& the *i3 ee0* i* er reat i&deed.

Thi* trai&i& +rora- -a0e* -e realied the alue o or0i&

toether a* a tea- a&d a* a &e e3+erie&'e i& or0i&

e&iro&-e&t, hi'h 'halle&e* u* eer -i&ute.

La*t !ut &ot lea*t I ould li0e to tha&0 - rie&d* e*+e'iall

tho*e ho or0 toether a* i&tere*t* at R.T.+a'0ai& Ltd.


5/33

5

A/0- .

Rollatai&er* i* o&e o the lare*t i&terated +a'0ai& 'o-+a& i&

the 'ou&tr ith it* *tate o the art i&ra*tru'ture i& #ara&a a&d

ar&ata0a,Rollatai&er i* 'ateri& to a ide *+e'tru- o +a'0ai&re6uire-e&t or the la*t ) de'ade*. It o7er* i&&oatie a&d

e7e'tie +rodu't ra&e* that *traddle all *e-e&t* o +a'0ai&

ro- +ri&ted li&ed 'artoo&, la-i&ated to -a'hi&er.

S,$,S.

Rollatai&er* Li-ited i&trodu'ed the 'o&'e+t o **te- +a'0ai&i& I&dia ! +roidi& 'o-+lete +a'0ai& *olutio&* to it*

'u*to-er*, *u'h a* 'arto&*, 8e3i!le +a'0ai&, e&i&eeri&.

Rollatai&er* i*:

1. Lare*t Produ'er* o li&ed 'arto&* i& I&dia.2. Oer 1((( Ma'hi&e* i&*talled i& I&dia a&d A!road.). 9a+a'it i* 5 -illio& +er a&&u-.4. Stateo theart i&ra*tru'ture a&d -a&ua'turi& a'ilitie*

+rodu'i& ide*t ra&e o la-i&ate* ;8e3i!le +a'0ai&-aterial*.

5.


6/33

=

MSS(.

To utilie 'utti& ede te'h&olo a&d *tate 1otheart 'o&trol

**te-* to e&*ure that all order* are deliered o& ti-e, o&

!udet, to -ai&tai& hih deree o e>'ie&' a&d attai&i&ter&atio&al *ta&dard*, a''ordi& to the 'u*to-er* e3a't

*+e'i?'atio&*.

Q0A+- P+$.


7/33

PrePress

Press

PostPress

Quality $ontrol

P, P,SS.

There are di7ere&t *te+* i& the +re+re** *e'tio& hi'h are :

i. Pla&&i&ii. De*i&i&iii. il- -a0i&i. Plate -a0i&

Pla&&i&:

Pla&&i& i* a +ro'e** o de'idi& *eeral thi& i& detail*

a!out e3e'utio& o a Bo! , !eore a'tuall *tarti& the or0.

I& +la&&i& e hae to de'ide :

1. A!out a &o. o thi&* re6uired or a Bo! li0e t+e a&d*ie o +a+er, &o. o 'olor*, t+e o i&0, +ri&ti&

-a'hi&e* a&d ?&i*hi& -a'hi&e* , *o that the Bo! i*

?&i*hed -o*t e7e'tiel a&d e>'ie&tl !eore the

delier ti-e.


8/33

C

2. A!out ra -aterial a&d the& ariou* *te+* to !e 'arried

out, -a'hi&e* o& hi'h the o+eratio&* ill !e 'arried out

a&d de'ide a!out he& ;ho.

Pla&&i& i* do&e ! +re+ari& a Bo! 'ard o& the 'o-+uterith the hel+ o *+e'iall de*i&ed *otare .

I e do&@t +la& a Bo! +ro+erl e ill lo*e the e>'ie&' o

the +la&t e -a lo*e the +ro?t a&d ill !e u&a!le to

delier the Bo! o& ti-e.

De*i&i&:

De*i&i& i* a +ro'e** o +la'i& all the te3t -atter, i-ae* a&d

illu*tratio&* i& a u&'tio&al a&d ae*theti' -a&&er ith the hel+ o

'o-+uter* u*i& DTP *otare li0e 9orelDra, illu*trator,

Photo*ho+, PaeMa0er, uar0 e3+re** et'.

Pre+ared de*i& i* *e&t to the 'u*to-er or a++roal.

Ater a++roal, *o-e 'orre'tio&* are do&e i &e'e**ar.

So-eti-e* 'lie&t are +re+ared a de*i& a&d *e&d ! e-ail

to the de*i&er. The de*i&er *et the de*i& o& the *heet.

Ater *etti& de*i&, a diital +ri&t o de*i& i* to the ualit

9o&trol de+art-e&t or a++roal the Bo! +ri&t. 9orre'tio&* are do&e i& &e'e**ar.

Set de*i& i* *e&d to ?l- -a0i& de+t. or i-ae *etter roo-.

il- Ma0i&: I& ?l- -a0i&, the i-ae i* deelo+ed o& a*iler halide* 'oated +la*ti' ?l- ith the hel+ o i-ae *etter.

The i-ae *etter i* to *et the i-ae o& to the +o*itie ?l-.

A& i-ae *etter i* a& ultrahih re*olutio& lare or-at

'o-+uter out+ut dei'e. Out+ut ra&e* i& idth u*uall


9/33

F

!etee& 12 a&d 44 i&'he*; re*olutio& i* !etee& 12((a&d

4C(( d+i. Due to hih *e&*itiit, ?l- to !e ha&dled u&der a "u*uall

red%*aeliht, i&*tead o i& total dar0&e** li0e -o*t

+hotora+hi' ?l-.

*orking o6 image setter :

G&e3+o*ed ?l- i* loaded o&to the i-ae *etter -a'hi&e i&

dar0 roo-. The 'o--a&d ie& a&d i-ae ill !e *et o&to the +o*itie

?l- i& 5 -i& e3+o*ure ith the la*er liht.

Di7ere&t +o*itie are -ade or di7ere&t 'olor*. Ater -a0i& the +o*itie, it +a**ed throuh the 'he-i'al

a*h a&d the& ith the ater a*hi& to re-oe the &o&

i-ae area ro- the +o*itie ?l-. Po*itie ?l- *e&t to the +late -a0i& de+art-e&t.

Plate Ma0i&:

O7*et Lithora+h i* a +la&ora+hi' +ri&ti& +ro'e** i.e. it u*e*

o& i-ae area a&d &o&i-ae area* are *e+arated 'he-i'all.

Hariou* *te+* o +late -a0i&:

Ste+ 1: il- +o*itie +re+ared i& i-ae *etter roo- are

re'eied a&d 'ut to their re6uired *ie ith *6uare ede*. All e o di7ere&t 'olor* are *u+er i-+o*ed o&e oer the

other ith e3a't rei*tratio&, ta+ed toether a&d *e&t to the

6ualit 'o&trol de+art-e&t or a++roal. Ste+ 2: A++roed ?l- +o*itie are &o +u&'hed i& e3a't

rei*ter ith the hel+ o +u&'hi& -a'hi&e o& the ri++er

*ide.


10/33

1(

Ste+ ): E3+o*ure :+o*itie are +ro+erl +la'ed o& ea'h o

the +late ith e-ul*io& J to J e-ul*io& 'o&ta't a&d ta+ed

ith ea'h other. The +late i* +la'ed i& the a'uu- do& ra-e ith +o*itie

u+o& it, la** ra-e 'lo*ed a&d a'uu- *it'hed o& to *etthe ?l- a&d +late +ro+erl.

GH liht *it'he* o& auto-ati'all a&d ta0e* a!out =(F(

*e'. i& e3+o*i& the +late +ro+erl. The e3+o*ure *ote&* the e-ul*io& hereer the liht *tri0e*

i.e. &o&i-ae area. Ste+ 4: "Pro'e**i&% Plate i* ta0e& out ro- the a'uu-

do& ra-e a&d +o*itie i* re-oed ro- it.

Plate 'a& !e +ro'e**ed either -a&uall i& deelo+i& *i&0 or i&

auto-ati' +late +ro'e**or.

There are three -ai& +ro'e**e* hi'h ta0e* +la'e i&

+ro'e**i& o +late:

I. Deelo+i&II.


11/33

11

• Ku--i&: A u&ior- laer o u- i* a++lied o&to the +late,

to +rote't the a&odied alu-i&iu- !a*e ro- o3idatio& a&d

other e&iro&-e&tal e7e't*.

• I GH +late ha* to !e -ade ,the& !a0i& *te+ i* re6uired to

i&'rea*e the lie o i-ae area o& the +late. Ater that +late

i* +u&'hed.

Pre Press Strengt7• ualit or0 or all o our 'u*to-er*.• Late*t *otare* or de*i&i&.

• Ne te'h&olo

• Trai&ed -a&+oer

• 9reatie de*i&*

Pre"ress 6acilities

1. Late*t *otare* 9orel dra

Ado!e Illu*trator

Photo*ho+

Auto'ad

2. I-ae *etter -a'hi&e to -a0e +o*itie or

&eatie.). 9o&ta't 9a-era to e3+o*e the +late ith +o*itie

a&d &eatie4. S'a&&er or hih 6ualit i-ae *'a&&i&.


12/33

12

Press

O7*et +ri&ti& +re** hae olloi& +art*:1. I&eed u&it2. Pri&ti& u&it). Delier u&it

n6eed unit:

It* u&'tio& i* to +roide 'o&*ta&t *u++l o *heet*. It haeolloi& +art*:

1. Pile !oard2. Sheet *e+arator). Sheet liter4. Sheet orardi&5. Side la a&d ro&t la=. Sheet dete'tor

Printing unit.

It +roide a& i-ae o&to the *u!*trate ith the hel+ oi&0i& a&d da-+e&i& roller*. It hae olloi& +art*:

1. Plate 'li&der2. la&0et 'li&der). I-+re**io& 'li&der4. I&0i& **te-

5. Da-+e&i& **te-=. Dri& **te-

!elivery unit.


13/33

1)

Thi* u&it 'olle't* +ri&ted *heet* ro- the +ri&ti& u&it.Delier u&it re-oe* ea'h *heet a&d *ta'0 a +ere't +ile o&the outeed ta!le.

$ommon "ress concerns

Ea'h +re** i* u*uall a**i&ed ith rou+ o o+erator*. Thereare olloi& *te+* u*uall u*ed i& o7*et +re**e*,*u'h a*

• eedi& the +re** *heet: +re** *heet* are 'ut i&to a'urate

*ie , hae *a-e thi'0&e** , *-, a&d &ot ri&0led or

*tu'0 toether. Pa+er *heet* are e&erall Boed 1/C to)/1= i&'h*e* i&to ?&al +o*itio&.thi* a'tio& 'au*e*rei*tratio&.

• Rei*teri& the +re** *heet : it i* auto-ati'all do&e !

*ide la a&d ro&t *e&*or*.

• Pre+ari& the +ri&ti& u&it: +late, da-+e&i& a&d i&0

**te- are arra&ed a''ordi& to Bo! 'ard.

• Delieri& the +re** *heet: delier u&it re-oe* ea'h

*heet a&d *ta'0 a +ere't +ile o& the outeed ta!le.

• There are *o-e other *te+* are al*o olloed i& o7*et-a'hi&e*.

1. I&0i& the +late2. Pre** +roo?&). A'hiei& +ro+er i&0 J ater !ala&'e4. O&li&e 'he'0i& o 6ualit o Bo!.

Speed of the machine depends upon the followin facto!s"

• -y"e o6 8ob#

• S7eet si9e

• &SM o6 t7e s7eet

• :ob re;uirment


14/33

14

Common P!o#lems Du!in P!intin "$

1# Set o66

2# Misregistration

3# Mottling

4# Scumming5# $olor variation

# Printing out

%# S7ade variation


15/33

15

,itshu#ishi diamond$-)))$L.$/

1. Ma&ua'turi& ear J 2((C2. S+eed J1=((( *heet +er hour). = 'olour o7*et +ri&ti&, o& li&e 'oati& , GH +ri&ti&, ) GH

la-+* e3te&ded4. Plate *ie C(( 1()(--5. 9o&trol J Auto-ati'=. 9olor *e6ue&'e J hite, ,9,M,$,te3ture, GH 'oati& or

+ri-er

Post p!ess

I& thi* *e'tio& +ri&ted *heet* are 'o&erted i&to ?&al+rodu't* a* +er 6ualit +ara-eter* o our 'o&*u-er* a&d

ISO *ta&dard*. There are ariou* -a'hi&e* are u*ed i&to+o*t +re** o+eratio&*:

La-i&atio& :


16/33

1=

the *heet . There are to t+e o la-i&atio& -a'hi&e -a&ual

or auto-ati'. I& 'a*e o -a&ual -/' the o&e ! o&e *heet i*

eeded ! ha&d* a&d out+ut i& the or- o roll, ater

la-i&atio& roll i* *loted ! ha&d*. I& 'a*e o the auto-ati'

la-i&atio& -/' the *heet are auto-ati'all eeded a&d*heet* +a**e* throuh the u-/ei'ol . #e&'e la-i&atio&

o& the *ura'e o *heet i* do&e i& the or- o roll. l 0&ie

**te- i* u*ed to 'ut the ru&&i& la-i&ated e! i&to *heet*.

Thu* *heet* are deliered to delier u&it. There are to

0i&d* o la-i&atio& -a'hi&e* are aaila!le i& rollatai&er*:

%& Lamination machine"

Auto laminator – YLL -3AWF

A++li'atio& J ?l- la-i&atio&

Produ'tio& *+eed J =( -eter/-i&.

Sie o e! J 1(((--

l 0&ie **te- i* u*ed to 'ut the e! i&to *heet*.

o&di& -aterial ei'olPre**ure J 1C(( 0ilo +a*'al

2. U0 coatin and 1a!nishin machine : A laer oultra iolet or ar&i*hi& i* a++lied to +ri&ted *heet* or


17/33

1

!oard*. GH 'oati& i&'rea*e the *hi&&i& a&d lo** o

*ura'e o +ri&ted !oard, it al*o i&'rea*e the lie o

+ri&t, *o that !oard !e'o-e* -oi*ture re*i*ta&t. The

'o*t o ar&i*hi& a&d GH 'oati& i* di7ere&t.

Towe! coate!$ TC $%)+A""lication "rimer coatingC 0 coating and arnis7ing

Production s"eed 5@mm

$ircum6erence %%@ mm E wit7 margin)

>@mmEwit7out margin)

Ad7esive Modi bond

3# Auto Die Cutte! ( 4o#st SP $ %)* $SEA""lication !ie cutting D ,mbossing

S"eed %5@@@ s7eets D 7our ne die Ma=# 1 carton

ne die u"on 1 lak7s

Auto Die Cutte! ( 4o#st No1a cut $ %)/A""lication !ie cutting D ,mbossing

S"eed


18/33

1C

4# 5olde! line! machine . ?older line mac7ine is used to insert

and "asting t7e liner in t7e carton# -7ere are t7ree kind o6 ?+M

mac7ines are available in t7e rollatainers. one cutC two cutC and

t7ree cut ?+M mac7ines# -7e s"eed o6 t7e mac7ine and si9e o6 t7e

carton de"ends u"on t7e cut available on cutting rollers#

5olde! line machine

A""lication ?olding C&luing and +iner "asting

Production S"eed 12@@@ carton D 7our

Ad7esive $7emilene

iscosity o6 Ad7esive @C@@@ 7ig7er

+iner used Met PetC 6oil laminer and "oly

?eeding Semiautomatic

5. $orrugation mac7ine : Thi* -a'hi&e i* u*ed to

+rodu'e 'orruated !oard* ro- +l e!. To e! are

-ou&ted o& roll *ta&d* a&d o&e e! i* i&*erted i&to

?&er* o the -a'hi&e a&d other i* +a*ted o& the *ide

o e! , ater that e! i* 'o&erted i&to *heet*.

Co!!uation ,achineProduction S"eed 3@@@ D 7our

?inger less mac7ine

Produce ? 6lute

+engt7 o6 Ply 4 inc7

Ad7esive Powder and ?evicol mi=


19/33

1F

=. ?lute lamination mac7ine : Pri&ted a&d 8ute are

la-i&ated ith the hel+ o ei'ol or adhe*ie. A

'o&eer **te- i* u*ed to a++li& the +re**ure o&

the la-i&ated *heet*.

,eiuan 5,6 %*/)A""lication ?lute +amination

Production s"eed 5@@@ s7eets D 7our

Ad7esive ?evicol

$ontrol Automatic

. Gluin and paste! machine J Thi* -a'hi&e i* -o&o

u&'tio&al , i& hi'h &o li&er i* u*ed. It i* u*ed to old

a&d +a*te the 'arto&.

4o#st 5olde! and Glue! ,achineAdhe*ie J Pedilite ei'olS+eed J )((( *heet* / hour9o&trol J Auto-ati'A++li'atio& J Klui& a&d +a*ti&

7ualit8 cont!ol.

ualit a&d i&*+e'tio& *e'tio& o the +la&t hae +ur+o*e to'he'0 6ualit o Bo! ro- ?r*t to la*t.I& 6ualit 'o&trol ehae to 'he'0 the 6ualit o ra -aterial, i&0, !oard,


20/33

2(

+ole*ter, li&er, a&d 'orruated !o3e*. To 'he'0 the 6ualito the -aterial*, e u*e olloi& e6ui+-e&t* :

1. To+ load *tre&th te*ter : to -ea*ure the *tre&th o

'arto& !o3.2. Sti7&e** te*ter : to 'he'0 the hard&e** o +a+er a&d

!oard.). *'ru! te*ter : to 'he'0 a-ou&t o *'ru! a'tio& o +a+er.4. Stati' ri'tio& te*ter : to -ea*ure the ri'tio&al or'e

duri& *tart u+.5. #eat *ealer : to 'he'0i& the *eali& o li&er*.=. KSM te*ter : to -ea*ure eiht o *u!*trate.. Thi'0&e** te*ter : to 'he'0 the thi'0&e** o +a+er.

C. G&ier*al i&di'ator" +h 4. To 11.( % : to 'he'0 the +h o

the +a+er, !oard ; lue et'.F. i*'o*it -eter : it i* u*ed to 'he'0 i*'o*it o lue.1(. 'o! te*ter : to -ea*ure 'a+a'it o -oi*ture i&

!oard.11. ! 4 'u+ te*ter : to -ea*ure i*'o*it o GH 'oati&,

ar&i*he* a&d +ri-er.

&ravure Printing SectionKraure i* a -aBor +ri&ti& +ro'e**. Oer 1C +er'e&t at all

+ri&ti& i& the 'ou&tr i* do&e ! raure. The raure i&du*tr

ha* e&Boed a relatiel *tead roth rate a&d, ith re'e&t


21/33

21

te'h&i'al ada&'e*, ill 'o&ti&ue to ai& a lare *hare at +ri&ti&

-ar0et.

Seeral i-+orta&t 'hara'ter*ti'* -a0e raure a& ideal +ro'e**

or Bo!* re6uiri& hih 6ualit a&d e3tre-el lo& +re** ru&*. There are e*+e'iall our -ai& de+art-e&t* are i&oled i& the

raure +ri&ti&:

• Pre Pre**

• Pre**

• Po*t Pre**

• ualit 9o&trol

Pre"ress

-7is is t7e "rocess be6ore "rinting# -7e design is sent o6 any "roduct by t7e "arty

to t7e gra"7ic design de"artment#-7e gra"7ic designer 7as been done somecorrection n t7e "re"ress section o6 gravure "rintingC t7ere are many terms

involves suc7 as .

• $olor correction

• -e=t correction

• Measurement

• Allignment

A6ter com"letion o6 t7ese correction C t7e design is sent to t7e "arty 6or t7ea""roval

6 a""roval is "assed t7en t7e design is sent to t7e gravure cylinder manu6acturing

ndustries#

G!a1u!e c8linde! desin


22/33

22

-7ere are 6ive basic "arameters s7ould be maintained during t7e cylinder design.

• A=is

• S7a6t

• !iameter

• $ircum6erence• ?ace lengt7

$ylinder c7aracterstics

1micron area o6 cylinder contains @ cells

1@ micron c7rome "lating

$ylinder 7ardness F 14@@ ve7icles

!octor blade 7ardness F %@@ ve7icles

6 cells are moreC t7en do not ac7ieve "ro"er s7ade#

6 cells are lessC t7en 7a""en a "roblem o6 6illing o6 ink

A* MA-,A+S ( &A0, P(-(& .o nk

o $ylinder

o Solvent

o Substrate

nk .-7ere are several ty"e o6 inks are used in gravure "rinting w7ic7 is based on

di66erent ink baseC Suc7 as .

1# !B @

2# +amiAll

3# +amito"

4# Polyamide

P0 based . 6or Polyester C /PP etc#

,DA . -oluene . M/'

4 . 4 . 2

inyl based . 6or "olyeter


23/33

2)

-oluene . PA . M,'

4 . 4 . 2

$ylinder S"eci6ication. $ylinder manu6acturer . s7reea8 otoC !el7i#

Pre"aration Met7od . ,lectro Mec7anical

1micron area contains @ cells

1@ micron c7rome "lating

Solvent S"eci6ication .

-oluene . medium drying M,' . 6ast drying

,DA . 6ast drying

PA . medium drying

M/' . slow drying

Substrate S"eci6ication . Polyester

/PP

Aluminium 6oil

$PP

Poly ,=trusion mac7ine

Pol8 P!epa!ation ,achine

• Manu6acturer . !&P *indsor

•Model . -?' 15@@D5@

• Ma=# s"eed . 12@ kg D7our

• Mac7ine si9e . 15@@ mm

• 3 ?eeder system . nnerC Middle G uter #

• -reatment system . $7rona treatment

• Pre"ared Poly . (atural G Milky


24/33

24

• Heating -em"erature . 1


25/33

25

-7e doctor blade is t7e device t7at removes t7e e=cess ink 6rom t7e smoot7 non

engraved "ortions o6 t7e image carrier# -7e name doctor blade is derived 6rom

t7e wi"ing blades used onductor rolls on 6latbed letter"resses# n common usage

ductor became doctor# -7e doctor blade must o"erate durably and e66iciently to

ensure t7e ;uality t7at is e="ected o6 gravure "rinting# !octor blades are also

used e=tensively in t7e "a"er coating "rocesses#

$7aracterstics o6 !octor /lade.

• Do'tor !lade a&le 45@F(@.

• -7ese are made 6rom "oly"ro"yleneC -e6lon or nylon in t7icknesses u" to #

@inc7#

• -7e blade itsel6 may be corroded by rust 6ormation w7en water based inks

are used#• !octor blades are generally manu6actured 6rom a s"ecial stri" steelC cold

rolledC 7ardened and tem"ered#

• ?or corrosion resistant a""licationsC stainless steel blades are used# -7ere are

some "lastic doctor blades in use# -7ey are used on coating rolls or to e=tend

t7e li6e o6 a worn cylinder#

• !octor blade 7older con6igurations vary wit7 "ress designs# Presses wit7 a

wide variety o6 cylinder si9es re;uire a wide range o6 ad8ustments to t7e

doctor blade 7older mec7anism# Holders may be curved or straig7t#

• $urved blades reduce t7e ri""le e66ect o6 uneven bolting tor;ue on t7estraig7tness o6 t7e wi"ing edge#

• i""le e66ects are also reduced w7en a blade is connected wit7 an aluminum

e=trusion#

&ravure m"ression oller.

-7e gravure im"ression roller is a 6riction drivenC rubber covered metal cylinder

t7at s;uee9es t7e substrate against t7e "rinting cylinder# -7e 6unctions o6 t7e

im"ression roller are 1) to obtain "ro"er ink trans6erC 2) to set t7e web tension "attern between "rinting units and 3) to "ro"el t7e web t7roug7 t7e "ress# -7e

contact between t7e im"ression rollerC web and "rinting cylinder is called t7e ni"#

-7e im"ression rollers are not geared to t7e "ressC but are instead driven by

6riction#

• -7e im"ression "ressure at t7e ni" is generally 5@2@@ P+ E5@1@@ 6or


26/33

2=

"a"er)#

• -7e im"ression roller is covered wit7 rubber or ot7er elastic "olymer#

• -7e ink is drawn out o6 t7e cells o6 t7e "rinting cylinder by a combination o6

im"ression "ressure and ca"illary action# -7is "rocess is aided by

electrostatic assist#• -7e im"ression roller and "rinting cylinder do not rotate at t7e same angular

s"eed because t7ey 7ave di66erent radii#

• /ecause o6 its elastomeric natureC t7e rotation o6 t7e im"ression roller is not

uni6orm#

• -7e local rotational s"eed decreases at t7e ni" due to t7e "ressure# -7is is

caused by t7e elastic elongation o6 t7e roller sur6ace at t7e im"ression "oint#

-7e general rule is to kee" t7e im"ression "ressure as t7e lowest t7at yields

acce"table "rint ;uality#

•ncreasing t7e im"ression "ressure brings t7e web into tig7ter contact wit7t7e "rinting cylinderC increasing t7e "robability t7at eac7 ink 6illed cell

contacts t7e substrate#

• HoweverC 7ig7er "ressure also "laces more stress on t7e "ress mec7anismC

bearingsC t7e web and t7e im"ression roller covering# n additionC 7ig7er

"ressure increases t7e de6lection or bending o6 rollers and cylinders and

leads to 7eat generation in t7e roller covering# /ot7 o6 t7ese e66ects are

detrimental to "rint ;ualityC "ress runability and roller li6e#

• -7e ma8or "rint ;uality "roblem wit7 gravure is t7e inability to trans6er ink

6rom every engraved cell to t7e web#• -7is can cause snow6lakingC missing dots or graininess#

• -7is mainly results 6rom sur6ace roug7ness o6 t7e substrate# Hence t7e better

"rinting ;uality on coated or su"ercalendered "a"er#

• ,lectrostatic Assist E,SA) was develo"ed to im"rove t7e trans6er o6 ink to

t7e substrate# ,SA a""lies an electric 6ield between t7e cylinder and t7e

im"ression roller# -7is is es"ecially e66ective 6or c7arged or "olar "igment

"articles used in t7e ink#

• -7e "rocess works well 6or bot7 "olar and non "olar solvents# ,SA 7as done

more to im"rove t7e ;uality o6 rotogravure "rinting t7an any ot7erinnovation# t 7as "rovided 1) im"roved "rint ;uality on a wider variety o6

substratesC 2) decreased wasteC 3) lower im"ression "ressuresC 4) 7ig7 "ress

s"eedsC 5) reduced im"ression roller 7eat buildu" and ) increased roller

li6e# n t7e absence o6 ,SA t7e ink tends to wet t7e sur6ace o6 t7e cylinder

and 7ence 6orms a concave meniscus in t7e cell#


27/33

2

> $+ -&A0, P(-(& MA$H(,

S"eci6ication.

• MDc (ame ,="ert PA$ 2@@@

• -y"e o6 "rinting 1) sur6ace "rinting 2)everse "rinting

• aw material /PPC PolyC PolysterC Met P,-

• Automatic unwinder roll stand

• Ma=#S"eed . 2@@ meterDminute

• MDc si9e . 11@@ mm

•

Ma=# cylinder circum6erence.


28/33

2C

• -e6lon s7eet

• Magnet in ink duct

• &ravure cylinder

• m"ression cylinder E sli" )

• !octor blade• !rying G c7illing unit .

• Hood drier

• $7illing roll

• ns"ection unit .

• Sto""er lig7t

• ns"ection 6lat lig7t board

• !elivering unit E rewinding unit ) .

•

(i" roller

Post p!ess Section "

SOL0ENT 4ASE LA,INATOR • S"eed. 15@mD minute

• $ylinder widt7. 11@@mm• m"ression. 24 kg#

• Ad7esive a""lied. 2g#

• !octor blade angle. @J

Ad7esive K HardnerEadditive) K Solvent

$A$ 2511 K $A$1511A K ,-H+, A$,-A-,

E 2@ '&) K E 3'& ) K E2@'& )

• iscosity o6 Hardner s7ould be lie bDw in ranging o6 11>

6 lessC add ad7esive#6 moreC add solvent#

'IG' PER5OR,ANCE AD'ESI0E S;STE,


29/33

2F

• $A$ 2511D$A$ 1511A is a solvent based two com"onent consisting o6

"olyuret7ane based ad7esive $A$ 2511 G "olyisocyanate additive

$A$1511A#

• $A$2511D$A$ 1511A used to lamination o6 6ilm to 6ilmC 6ilm to 6oilC 6ilm to

metali9ed 6ilmC 6ilm to "a"erC 6ilm to board etc#• ,=cellent bond strengt7 G7eat resistance#

• $ontains 7ig7 $#

• 0sed mainly soa" wra""ersC "ackaging li;uidsC s"ices G detergents#

Mi=ing atio .

• 1@@ "arts by weig7t $A$ 2511 to 15 "arts by weig7t $A$1511A#

• $ylinder based on 15@ +"i E@ +"c )#

• ,lecrically etc7ed cylinder cell de"t7 4555 microns#

SOL0ENTLESS LA,INATION ,AC'INE 9SC'A0I:

+amination means to stick two materials wit7 t7e 7el" o6 an a""ro"riate ad7esive#

And in anot7er wordsC Solvent less +amination means to stick two materials

wit7out t7e 7el" o6 any ty"e o6 solvent like et7yl acetate#

• Ad7esive are used to stick two materials e#g# ($

• Hardener are used to 7ard t7e ad7esive e#g# H

A!H,S, HA!(,

Materials . ($ H

-em"r . @5Jc 454Jc

&a" bDw t7e steel roller F @#< mm#

-7e glue is a""lied at least 1 mm on bot7 t7e edges o6 t7e web w7ic7 is stick to

eac7 ot7er#


30/33

)(

• t is used 6or "a"er converting bonding a""lications#

• Pro"erty. ,=cellent wet tack#

• S"eci6ication .

i# $olor . w7ite

ii# ?ilm . elasticiii# iscosity . 4@@@@@@ mPac at 25Jc

iv# "H . 4

v# Solid content . 525L

vi# !ensity . 1#@5 gDcm3 at 25Jc

vii# Setting time . s7ort

Inspection ,achine

INTRODUCTION"$

ns"ection mDc are used to 6ind t7e error in "rinting during "rinting # t saves t7e

t7e time in 6inding error #in ins"ection mDc t7e s"eed o6 roll s7ould be 7ig7 so

t7at t7e image can be ke"t constant and easily identi6y t7e mistek #-7e

ins"ection mDc work on t7e strobosco"e lig7t#t also "lay t7e big roll #durring

running o6 mDc it s7ows us t7e material in sto""age Cso t7at we can easily

identi6ing t7e mistake and remove it #

-7ere are t7ree ty"e o6 ins"ection mDc in t7e gravure section#

1# Small 6ully automatic mDc E(o# o6 mDc 2)

2# +arge automatic mDc

3# +arge manual mDc 1st two mDc are near t7e laminion section and ot7er two are a7ead o6 "rinting

mDc #-7ese mDc are also used to correct t7e roll and only one 8oint is allowd

between one reel and it will be u"to 2@L#

,2c structure .


31/33

)1

• 0nwinder unit

• (i" roller

• Strobosco"e

• ewinder unit

-ension 6actor .

0nwinder tension ewinder tension

6 rewinder tension is more C t7en rewinding roll is not "ro"erly rolled#

Slittin machine "

Int!oduction"$ n slitting mDc we cut t7e 8ob 6rom single s7eet wit7 t7e 7el" o6

7ig7ly s7ar"ed blade# n t7is mDc no# o6 blade are used according to 8ob# 6 one

s7eet 7aving two u"s are used t7en we use 3 bladeEtwo blade at edge and one in

center)

,odel "$ Ult!aslit O'P

-7ere are 6ollowing section in slitting mDc .• n6eed section

• /lade section

• !elivery E coiling section )#

• -ension 6actor .

• 0nwinder tension ewinder tension

• 6 rewinder tension is more C t7en rewinding roll is not "ro"erly rolled#


32/33

)2

7ualit8 cont!ol"

ualit a&d i&*+e'tio& *e'tio& o the +la&t hae +ur+o*e to

'he'0 6ualit o Bo! ro- ?r*t to la*t.I& 6ualit 'o&trol e

hae to 'he'0 the 6ualit o +ri&tred -aterial, +ol,Ra

Material i& the *tore a&d other 6ualit *ta&dard* o

-aterial*.

There are olloi& e6u+-e&t* are u*ed i& raure 6ualit'o&trol *e'tio&:

• 9O te*ter : To 'he'0 the #u-idit o Poru* Material.

• #ot Melt Plate : To A&al*i* Di7ere&t Laer* o Pol.

• Sti7&e** Te*ter : To 9he'0 the #ard&e** o the 8e3i!le

-aterial.

• S+e'tru- 9olor Mat'hi& 9a!i&et : To o!*ere di7ere&t

e7e't* o Di7ere&t 0i&d o liht.

• ri'tio& Te*ter : to 9he'0 D&a-i' a&d Stati' ri'tio& O&8e3i!le Material.

• #eat Seal Te*ter : to 9he'0 the o&di& Stre&th o Ra

Material.

• O+tal Te*ter : To 9he'0 o+a'it o Met PET , Pol A&d

Other ra Material.

•


33/33

). o&d Stre&th4. Seel Stre&th

Rollatainers Report

Documents