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Films Division
Engineering Division
Holography Division
Converting Division
Cylinder Division
Chemical Division
My orientation covered the Films Division, Converting Division and Cylinder Division.
FILMS DIVISION
The following are the products made in the films division. These films are then
supplied to the converting division for printing, lamination, pouching.
FLEXOPP
RANGE 8 - 75 MICRONS AVAILABLE IN:
PLAIN, HEAT-SEALABLE, METALLIZABLE, MATT, PEARLISED, CAVITATED, OVERWRAP,
WHITE OPAQUE, SPECIALTY FILM GRADES
FLEXOPP Performing Properties:
1. Good mechanical strength
2. Good chemical resistance
3. Good dimensional stability
4. Excellent barrier against water
5. Superior optical clarity
6. One or both side heat sealable
7. Good stiffness
8. Resistance to tear and abrasion
Applications
1. Packaging & Conversion
2. Metallizing
3. Industrial Coating
4. Printing and Lamination
5. Photo Albums
6. Encapsulation
7. Overwraps (CDs, Cigarettes)
8. Synthetic Papers
9. Holography
10.Adhesive Tapes
11.Textile Bags
12.Hot & Cold Antifog
13.Cables over wrap
14.Reams/Sheets wrapping
15.Confectionery packaging
16.Biscuit/Sandwich over wrap
17.Inner wrap
18.Embossing
19.Anti-fog (Food products)
20.Thermal Lamination
21.Shrink wrap and many more
Annum (35 Million Lbs) and can be supplied in widths upto 3000 mm, thickness
range of 18-200 microns. The film can be offered with corona treatment on either
one or both sides.
FLEXCPP RANGE 18 - 200 MICRONS
AVAILABLE IN :
PLAIN, HEAT-SEALABLE, METALLIZABLE, POLISHED, MIRROR, EMBOSSED SURFACE,
GLOSS / MATTE FINISH, STIFF, FLEXIBLE, CLEAR, OPAQUE VARIETIES
FLEXCPP Performing Properties:
1. New aesthetic possibilities for enhanced shelf appeal
2. Good gloss, transparency and heat sealability
3. Versatile structural properties
4. Good oxygen and moisture barrier
5. Customisable for special applications
Applications
1. Packaging & Conversion
2. Food Wraps
3. Lamination
4. Anti-fog
5. Candy/confectionery Wrap
6. Garment Bags
7. Retort Packaging
8. Stationery Packaging
9. Vacuum Metallization
10.Deep Freeze Application
11.Over Wrap
12.Floral Wraps, and many more
2.
3.
4.
5.
6.
7.
8.
9.
CONVERTING DIVISION
The converting division consists of:
Printing
Lamination
Slitting
Pouching
W.P.P.
Lab
Printing
Printing is used to create a visible identifiable image consistently, for a large
no. of impressions.
In Uflex, there are 2 types of Printing processes:
Roto-Gravure Printing
Flexography
Roto-Gravure Printing
It is a type of intaglio printing process; that is,
it involves engraving the image onto an image
carrier. In gravure printing, the image is
engraved onto a cylinder because, like offset
printing and flexography, it uses a rotary
printing press.
In direct image carriers such as gravure
cylinders, 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. The doctor blade scrapes the cylinder before it makes
contact with the paper, removing excess ink from the non-printing (nonrecessed) areas and leaving in the cells the right amount of ink required: this
tool is located quite close to the paper so that the ink left in the cells does
not have enough time to dry. Next, the paper gets sandwiched between the
impression roller and the gravure cylinder: this is where the ink gets
transferred from the recessed cells to the paper. The purpose of the
impression roller is to apply force, pressing the paper 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 (Figure 1). Then the
paper goes through a dryer because it must be completely dry before going
through the next color unit and absorbing another coat of ink.
Because gravure is capable of transferring more ink to the paper than other
printing processes, it is noted for its remarkable density range (light to
shadow) and hence is a process of choice for fine art and photography
reproduction, though not typically as clean an image as that of offset
lithography. Gravure's major quality shortcoming is that all images, including
type and "solids," are actually printed as dots, and the screen pattern of
these dots is readily visible to the naked eye.
Gravure is an industrial printing process capable of consistent high quality
printing. Since the Gravure printing process requires the creation of one
cylinder for each colour of the final image, it is very expensive and best
suited for high volume printing.
A wide range of substrates such as polyethylene, polypropylene, polyester,
BOPP, etc. can be printed in the gravure press. Gravure printing is one of the
common processes used in the converting industry.
Advantages
The rotogravure printing process is the most popular printing process used in
flexible-packaging manufacturing, because of its ability to print on thin film
such as polyester, OPP, nylon, and PE, which come in thicknesses of 10 to 30
micrometers.
Other appreciated features include:
Disadvantages
Shortcomings of the gravure printing process include:
S.n
o.
Machine
Name
No.
of
Colo
urs
Made
in
Max.
speed
(m/min
)
Cylind
er
size(m
m)
Rotomec(ol
d)
250
Sungan
Italy
S.
Korea
3
4
5
8
10
8
Italy
Italy
Flex
450
300
200
Italy
400
Italy
400
Cerutti
Schiavi
Rotoflex
Rotomec(n
ew)
Rotomec(n
ew)
Rotomec(n
ew)
400
Ebeam
Italy
Germa
ny
1060
1200,
1060
1280,
1370
1280
690
1280,
1370
1280,
1371
1280,
1372
500
6
7
300
CYLINDER DIVISION
The cylinder division consists of the following departments :
1. Art department
2. Pre Press Department
3. Production
a. Machine/Tool/Lath Section
b. Plating Section(Nickle/Copper/Chrome)
c. Polish Master Section
d. Engraving Section
e. Proofing Section
The first step of Gravure is to create the cylinder with the engraved
images that need to be printed: the engraving process will create on the
cylinder surface the cells that will contain the ink in order to transfer it to
the paper. Since the amount of ink contained in the cells corresponds to
different colour intensities on the paper, the dimensions of the cells must
be carefully set: deeper cells will produce more intensive colours whereas
less deep cells will produce less intensive ones. There are three methods