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Now and Future of

Gravure, Flexo and Digital printing

Press, impressively!

ORIENT SOGYO CO., LTD.

Hidenori Harada

at Pullman Hotel - Jakarta

Nov 19, 2014

Now and Future of

Gravure, Flexo and Digital printing

Flexible Packaging - Trends and Business keys

Machinery and Technology history of Gravure ,

Flexo and Digital printing

Pros and Cons of each printing methods

& Future prediction of Package printing

ORIENT SOGYO CO., LTD All rights reserved

• INDONESIA in the WORLD

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Indonesia – Business environment

Growth rate (predict) %

China

India

Indonesia

Mexico

S.Korea

Turky

USA

GBR

Canada

Australia

S.Africa

Spain

Brasil

Japan

Whole world : 3.7% in 2015 3.9% in 2016

Quote : OECD / Nov 2014

• INDONESIA’s GDP per Person

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Indonesia – Business environment

Indonesia : Expected constant growth and Very rapid Inflation

• WORLD trend

Developed countries rely on Emerging Countries

economic growth (China Risk, Russia isolate)

Low interest ＆ Financial game : floating fund

・ INDONESIA in the WORLD

Largest population in SE Asia： 2.5 million ++

Still poor Social infrastructure

Rule of Law, Transparency, Anti-corruption

Week Rupiah (IDR) ~ peg to USD

Gap between Rich and Poor : expand Middle layer

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Indonesia – Business environment

Package exhibition in 2014 • Interpack is the largest

exhibition about Packaging

in Dusseldorf Germany

held in 2011 and 2014

• Japan and ASIA’s packaging in the World.

• Any New idea, New materials, New movement about Flexible packaging?

Package exhibition in 2014 • Tokyo Pack is the largest

packaging show in Asia.

Re-sealable, Long-life packages

Convenient and Eye-catching design

High barrier, recycle materials

Faster packing process

Comply new Environmental regulations

Global extension by JPN Convertors

★ ORIENT First participate with FLEXO

New Business matching for INTERPACK New Package Technologies and Ideas for TOKYO PACK

Flexible Package trends and business key words

ORIENT SOGYO CO., LTD All rights reserved

Save Food

Value premium

VOC emit

Toluene free

Food Safe

Water-base

Energy save

Clean room

Carbon foot print

Easy peel

Easy cut

Standing display

High barrier

Bio Material (PLA)

Life Cycle Assessment

Microwave pouch

Sustainable growth

ECO - Green theme

Package functional

Continuous /Improving

Creating

Universal Design

Personalized pack

Retail Logistic

Variable print

Tractability

Three different Printing Methods

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DIGITAL FLEXO

G, F, or D… Compete each other? Or Co-exist?

GRAVURE

Principal of Gravure print and Flexo print

Metal cylinder with

High pressure

Flexo print Gravure print Resin plate with

very Light pressure

Anilox

Plate-mounted cylinder

Impression roll

Gravure cell Flexo plate

Relief

History and features of Gravure printing (1)

【Products by Gravure】

… Magazine (Before)

… Flexible packaging (Now)

… In-mold label, Printable Electronics (Now)

【Remarkable Features】

・Vivid color expression

・High Color density

・Long-run stability

・Simple structure - Fewer of driven rollers

× A Lots of solvent use

Fire accident

Labor health

Odor retention / transfer

Gravure printing Technologies (Past)

【 Past - developed Technologies of Gravure Printing】

• Cylinder engraving & plating process

• Tension control for variety of film kinds

• Doctor blade assembly

• Inking supply system with overflow Circulation

• impression rubber pressurizing

• Hot air blow drying system

• Gravure ink – Color-phase, Glue-reaction, Friction

• Register control system & Stroboscope monitoring

Some remain the same styles for a long time since Gravure Printing was born

Gravure printing Technologies (Current)

Develop & Utilize in Japan. Exported to Indonesia after a certain period.

【Resent develop (Last 10-15yrs) Technologies of Gravure Printing】

• Non Toluene ink, Non MEK ink, High-Density ink

• Multi-purpose ink for lamination

• “Water-resolve” ink (Alcohol rich 30-40%)

• Direct / Laser engraving cylinder process

• 100% area Inspection system

• Sectional Drive (Electric/Virtual Line shaft) system

• VOC burn / recycle system – Heat recycle system

• Trolley assembling system (European)

• Three-roll / Sleeve impression system

Functional

Environmental

Gravure printing Technologies (Future I)

【 Printing Press Manufacturer 】

• Energy saving – esp. Drying heat , Drive Motors, Blowers, Lights

• Ink & Solvent saving (Less volume use, CCM, Accurate visco keep)

• High speed print for Long-run jobs

• Ultra quick change-over for Multi-short run jobs

• Zero/Low wastage (Mis-register, Splice, Streak, Dust, Mis-match color)

• Easy Operation – Instructive / Fool-proof / Production Management

• Auto-cylinder cleaning

• Auto material handling

• In-line Laminating process

Gravure printing Technologies (Future II)

Still long way For Ideal Gravures Printing

【Ink maker, Cylinder maker, Inspection system maker】

• Very-low Alcohol contain Water-base (10-20%) ink

very low VOC emissions

No labor health problem / No fire accident

• Functional / All purpose Gravure ink

• Super shallow depth engraving with High-resolution cylinder

• Solution-providing Inspection system

• High barrier material – non-Alu Foil, Transparent Metalize (Deposition)

• Eco material – PET 8micro, PLA (Bio film), Recycle

Holding Big potential of Growth

State-Of-The-Art Convertor

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Press, impressively

Golden Cylinder Award

a) FUJITOKU (Nagoya) 200m/min in Water-base Gravure

State-Of-The-Art Convertor O

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Press, impressively

b) CHUKYO KAGAKU (Nagoya)

Short-run (Less 4000m x 8 items) within 8hour

by ALL CMYK process printing with 250lpi engraving

Common Trigger

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LOCAL Env. issue : Labor Health & Air Pollution

State-Of-The-Art Convertor O

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c) SEIKO (Osaka, Sendai, Tsukuba)

Very Clean Factory environment

White Machine with Whole Stainless Floor (Mirror-finish)

Air-con outlets and Dry-Fog sprinkle nozzles

Clean floor immediately when Ink dripped.

Trolley system has been very common

Gravure cylinder is Shafted type

European Gravure press maker

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Concentrated Operation desk

Max Speedﾞ ： 450m/min

Wed width : 800 - 1300mm

Still Air-shaft

Register control : One-pixel camera

History and features of Flexo printing (1)

【Products by Flexo】

… Card board box

… Label and Seal

… Folding carton

【Remarkable Features】

• Simple plate process – resin / rubber

made

Complicated mechanical structure

• Little press pressure for ink transfer

Printable for variety of materials

(paper, non-woven, foils, film etc)

・Little ink usage – High color density

Fast ink dry on the plate

第１＆２号機 ユーザ

Flexo products in the Market

Lami-pouch, Label, LDPE, Wrap paper and so on…

History and features of Flexo printing (2)

【Key Technology of Flexo Printing in Flexible packaging】

• Flexo Resin Plate process (CTP)

• Flexo Elastomer plate / sleeve process

• Anilox roll

• Flexo Ink (e.g. Water-base ink, Boil-Retort applicable, UV, EB)

• Cushion adhesive tape

• Multi-axis Drive-control (gear-less) & Kiss-touch control

• Chamber doctor inking

• Plate-Mounter

Esp. Resin Plate & Anilox roll Quality improvement contribute to Bigger FLEXO potential !!

Flexo plate process

•

No Chrome, Copper plating process. Light material handling & Small

equipment EASY In-house plate-process

Anilox roller

•

No Chrome, Copper plating process. Light material handling & Small

equipment EASY In-house plate-process

【Gravure Print】 vs 【Flexo Print】

Solvent base Gravure

Water base Flexo Xpress

Work Environme

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Hazardous & Fire risk

Very clean &

No explosive

VOC emit A Lots of VOC

Without facility Very Very low

Cylinder / Plate

process

Direct Engrave / Laser Engrave plus Cu

Cr plate

a) Laser image +UV expose

b) Direct Laser

【Gravure Print】 vs 【Flexo Print】

Solvent base Gravure

Water base Flexo Xpress

Quality Key Gravure Cylinder + Doctor + inking

etc.

Resin plate + Anilox roll + Kiss-touch

pressure

Color range

Commonly 175lpi 150lpi, 133lpi or

120lpi

Drying Hot air blow

【Gravure Print】 vs 【Flexo Print】

Solvent base Gravure

Water base Flexo Xpress

Balance ink in the

pan

10～15 litter per color after Cylinder

wash

Less than 1 litter

plus Ink piping length

Change-over＋

Cleaning

Splashed ink

＋ Furnisher

＋ Cylinder

＋ Ink Pan

Ink Drain from Close Chamber

Xpress Register control

1. 基本原理 ： 三角マークによる隣色ツーマーク制御

2. 貼込みプレート原点（トンボ) ＝ 駆動系 （回転位相) 原点

Gravure vs. Flexo : Balance ink

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What Flexo Xpress can do

Super short run

Water-base ink

極小ロット多品種

水性インキ

Expand FLEXIBLE PACKAGING demands

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New key : [Re-active idea] [Premium marketing]

And [Local-intimacy marketing]

【従来】

<former> Not necessary all the packaging design would not become actual package…

<New> Showing more choices to Consumer and they will determine what is the best!

Minimum Quantity of bags supplied

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JUST IN TIME practice at Flexible Packaging

JAPAN Gravure – Business environment

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What is Short – run job ?

Only 2kg rice consumption!

Job become Shorter than shorter 2000m/job ??

JAPAN Gravure – Business environment

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What is Private brand items ?

Private brand items are sold cheaper than National brand !!

Germany (EU) market case –Drug store-

・ Same Brand ground COFFEE powder pouches stood aside

each other

One was Gravure, The other was Flexo

・ Most of FLEXO items co-exist with GRAVURE, 150lpi screening

image is required.

High quality required item : Shampoo pouch

even a Printing industry person has to look closely to tell

difference

・ LLDPE (sanitary items) is needless to say done by CI flexo

not easy market by Gravure Printing in EU

EU – Interpack 2014 - review

★ Approx. ６０－７０％ : Using both GRAVURE and FLEXO

★ Approx. 2０－３０％ : Own only FLEXO

★ Approx. 10% : Own only Gravure

Type of Package, Packaging design are NOT the factors of

choosing GRAVURE or FLEXO.

There is common understanding that Gravure is for Quality.

Flexo is for Cost and productivity advantages.

ESKO GRAPHIC「HD FLEXO」screening technology enhance

FLEXO print quality drastically（Last 4-5years）

～ How do you decide if you print by Gravure or Flexo ～

EU – Interpack 2014 - review

There are NO intentions to develop Water base Gravure.

Already try Water base FLEXO in Paper items

FLEXO CI is realized as Quick changeover by sleeve system and Register stability but pretty much Human Unfriendly system

⇔ vs Gravure requires Long film path and cause wastage

Flexo comes FIRST. Gravure, as the second choice, replaces

some high quality items from Flexo jobs.

～ How do you decide if you print by Gravure or Flexo ～

EU – Interpack 2014 - review

Gravure Cylinder : Euro 400-450 / piece.

Flexo plate : Euro 300-350 / plate

Definition of Short run job : 1000~12000m / item

～ How do you decide if you print by Gravure or Flexo ～

Digital Printing

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As Art-work Color Proofer use : Color Management

As actual production use : Gravure Cylinder companies

HP ： Indigo series

LANDA (Israel)

Mimaki (JPN)

Roland (Germany)

Conclusion in IND

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1) Gravure will maintain the main stream!

2) Whole package demand will increase according to economic growth 3) Paper & LLDPE print items may take place to FLEXO. But not much existing laminate-pouch 4) Labor health / Air pollution issue / regulation will enhance Non-toluene ink usage or VOC regulation, or even FLEXO growth 5) Unless INDONESIA market get more diverse to create New demands on Flexible packaging, Digital print would not be your solution.

Flexible Packaging Seminar

at PULLMAN HOTEL, Jakarta Nov 19, 2014

THANK YOU FOR LISTNING

ありがとうございました。

terima kasih

ORIENT SOGYO CO., LTD All rights reserved

ORIENT SOGYO CO., LTD All rights

reserved