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KP KAMIL PACKAGES (PRIVATE)LIMITED

Group Members: (6G)

y Muhammad Yaqoob Akmaly Muhammad Arsalan Saleemy Adeela Majeedy Marium Rana

Submitted to: -

Sir Irfan Ali


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ABSTRACT

As our topic is on Layout Process and for this we visit Kamil Packages to make a report.

In December 2010 APH started a side business of Gravure printing and finally startoperating in the end of January 2011. This business started in the name of grandfather

Kamil and business named Kamil Packages (Pvt).Ltd. This business started on thefuture market demand and started with the partnership among all brothers. KPS started

the business with the same vision, same working departments and layout process.

KP dealing with many companies but there majors clients are Kolson, Shan, Danpak,Ashrafi foods and etc. KP not just treat them as a client but they are also give value to

them. KP makes relation for long term and corporate them in every stage.

The analysis of production process we found out that their production process is well

managed and organized as they have very skilled employees and labors also they havetheir plant at ideal location in context of transportation cost saving as their plant is

located near to the port as well as closer to their major clients also it is very feasible forthe workers.

KP is having a good working environment and always gives importance to the employees

and facilities. In organization the value to the employees are very important and this whatKP always gives to their workers that we saw in the organization. The organization is

serving since 5 months but what we saw there between the workers in team workingcooperating between each other to achieve success.


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Table of Contents

Introduction................................................................................................................... 3

Clients of KPS ............................................................................................................... 5

About Gravure Printing................................................................................................ 6

How job Order get done................................................................................................ 7

Production Process ........................................................................................................ 8

PP (Raw Material) ........................................................................................................ 9

PP (Printing Process) .................................................................................................. 10

PP (Lamination Process) ............................................................................................. 12

PP (Slitting Process) .................................................................................................... 13

Conclusion ................................................................................................................... 14

Recommendation......................................................................................................... 14

References.................................................................................................................... 14


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KAMIL PACKAGES (Private) Limited

Introduction

Akmal Print House (Private Limited) was created on March 19 1963. It is standing today

as the finest printing the packaging pharmaceutical materials company in Karachi.

As a leading pharmaceutical printing company we make a real difference in the global

health care by true color in life through printing and especially to the developing world.

We believe that this is both an ethical imperative and key to success. Companies that

respond sensitively and with commitment by changing their business practices to address

such challenges will be the leaders of the future. APH operates mainly in Designers,

Printers and Binders.

In December 2010 APH started a side business of Gravure printing and finally startoperating in the end of January 2011. This business started in the name of grandfather

Kamil and business named Kamil Packages (Pvt).Ltd. This business started on the

future market demand and started with the partnership among all brothers. KPS started

the business with the same vision, same working departments and layout process.

APH deals in value, some of our key brands include Augmentin, Panadol, Seretide,

Betnovate, Iodex, Ultimate Plus Lenses and many more other pharmaceutical companies.

Corporate Department

M. Akmal ----- Managing Department

S.M. Rafi ----- Manager

M. Afzal ------ Technical Director

Zafar Safi ------ Q.C Director

Mission Statement From M. Akmal --- Managing Director

KPS mission is to provide quality printing. We believe in value performance. We always

try to attain success and make our standard as compare to multinational company. We

always work with passion.


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Duty of Manager

Duty of mine is to look for the products quality and to check the delivery time. My staff

trusts me and I trust my staff. I am controlling over 150 staffs daily and always have to

check them. The Delivery Challan is also issued by me. Without this challan the delivery

of good cannot be possible. I always have to look out the transport availability and

always deliver my goods on time in present and the future.

Spirit of KPS

y Performance with IntegrityDelivering on promises with organizational and individual trustworthiness.

y People with PassionInspiring, motivating, and enabling people to do their best work.

y Everyone Committed, Everyone ContributingEnabling, encouraging, and allowing all employees the opportunity to make meaningful

contributions and succeed on merit.

y Develop Self and OthersLearning continuously and developing professional potential and ability. Leaders act as

teachers, coaches, and champions of development, creating career-long learning across

the organization.

Our Press Location

A/70 Mangopir Road,

S.I.T.E opp. Valika Hospital,

Karachi 75700. Pakistan

Telephone: 2595305-8

Fax: 2595309


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CLIENTS OF KPS

Some of our major clients are

DANPAK

SHAN FOODS

ASHRAFI FOODS

WONDER FOODS

KOLSON

TAPAL


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Gravure Printing:

Printing processes used for catalogs, magazines, newspaper supplements, cartons, floor

and wall coverings, textiles, and plastics. The Bohemian Karel Klc made photogravure a

practical commercial process in 1878. An image is etched in the copper surface of the

printing cylinder as pits or wells of different depths. In rotogravure printing, the cylinder

rotates through a trough filled with fast-drying ink. A thin steel doctor blade removes the

ink from the surface but not from the wells. The cylinder comes in contact with the paper,

which draws the ink out of the wells. Because of the various depths of the wells, a full

range of tonal values can be printed; in reproducing illustrations, gravure comes closest to

simulating continuous-tone copy. In colour printing, a separate cylinder is prepared for

each colour.

Advantages:

Gravureis the quality printing process producing fantastic and constant reproductions

throughout the print run because the secret of the gravure process lies in the cylinder.More robotics and total plant computer control systems will bring many further

advantages for gravure. It is very simple printing process and can produce millions of

perfect bags at enormous speed.

Another useful advantage of gravure is that it produces superb colors and gloss on

relatively low quality film, which can bring big cost saving.


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HOW JOB ORDER GET DONE

Firstly, customer orders the amount of material they want then via E-mail, telephone or

through other medium. Then the production department checks their capacity and

available resources and their production schedule (time of fulfillment of order) after it

company communicate with the supplier for the acquisition of raw material and after the

receiving of raw material process get starts and production department try to complete the

job as soon as they can. After the completion of the order it supply to the respective

customers through trucks or other medium of transport.

PRODUCTIONPROCESS

The steps required in our process include raw material receiving, raw material quality

control test, printing, printing material quality control test, lamination, quality control,

slitting and finally quality assurance test. The details of these steps are given below.

Purchase Orderfrom Clients

Work Order

PurchaseOrder from

SupplierProcess

Delivery

of Order


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PRODUCTION PROCESS

Raw Material

receiving

Raw MaterialQuality Test

Printing

Printing MaterialQuality Test

Lamination

Quality ControlTest

Slitting

Quality Assurance

test


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Raw Material

We use the combination of BOPP and MCPP solvent. The details of these materials are

given below.

Biaxially Oriented Polypropylene (BOPP) films are used in

an almost limitless array of flexible packaging applications,

pressure sensitive tapes,labels, stationery, metallizing,

consumer products and a wide variety of non-packaging

uses.

BOPP Products has an extensive product line available in a

wide range of film gauges and desired performance

properties. BOPP films are manufactured by proprietary coextrusion and biaxial

orientation processes, which produces films with excellent gauge control, consistency and

roll profile.

"Biaxially Oriented" means that the polypropylene film is stretched in both the machine

direction (MD) and across machine direction (AMD). Because of its superior strength at

low gauges, flatness, clarity and excellent printability

CPP film & MCPP are widely used as printing, sealing material for flower and food

arrangements, detergents and packing dry foods such as tea, crackers, biscuits, dressing,

etc.

CPP film adopts a special processing of 3-layer co-extrusion, and is a heat-sealing

material used for variety of packaging purposes. It can be laminated with BOPP and

BOPET or directly packaged after printing.

CPP film has high transparence and gloss, low COF, low sealing temperature, high

sealing strength.

It took 2 months in receiving the raw material from the supplier as this time include

shipping process and the process at the port.

Raw material imported from China, Dubai and Egypt.


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Printing Process(YONG FONG MACHINERY-China)

1000 kg of raw material took 15 hours in printing process.

Cost of printing per kg is Rs.400 is means the printing cost of 1000kg will be 4lac.

The major unit operations in a printing operation are:

y Image preparationy Plate makingy Printingy Finishing

y Image PreparationImage preparation begins with camera-ready (mechanical) art/copy or

electronically produced art supplied by the customer. Images are captured forprinting by camera, scanner or computer. Components of the image are manually

assembled and positioned in a printing flat when a camera is used. This process is

called stripping. When art/copy is scanned or digitally captured the image is

assembled by the computer with special software. A simple proof (brown print) is

prepared to check for position and accuracy. When color is involved, a color

proof is submitted to the customer for approval.


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y Plate MakingFlexographic and letterpress plates are made using the same basic technologies

utilizing a relief type plate. Both technologies employ plates with raised images

(relief) and only the raised images come in contact with the substrate during

printing. Flexographic plates are made of a flexible material, such as plastic,

rubber or UV sensitive polymer (photopolymer), so that it can be attached to a

roller or cylinder for ink application. There are three primary methods of making

flexographic plates; photomechanical, photochemical and laser engraved plates.

y Printing PressesThe five types of printing presses used for flexographic printing are the stack

type, central impression cylinder (CIC), in-line, newspaper unit, and dedicated 4-,

5-, or 6-color unit commercial publication flexographic presses. All five types

employ a plate cylinder, a metering cylinder known as the anilox roll that applies

ink to the plate, and an ink pan. Some presses use a third roller as a fountain roller

and, in some cases, a doctor blade for improved ink distribution.

y InksFlexographic inks are very similar to packaging gravure printing inks in that they

are fast drying and have a low viscosity. The inks are formulated to lie on the

surface of nonabsorbent substrates and solidify when solvents are removed.

Solvents are removed with heat, unless U.V. curable inks are used.

Ink comes in drums which are weighted in kilos. 1000kg printing includes 440mg

approx ink. 1 kg cost Rs.80

After the process of printing the film roll transfer to the Lamination department.

Printing Material test:

After printing process the Curing test is done to test the printed job and eliminate the

defected material.


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Lamination

The process of applying a film of plastic on the surface of any item is known as

laminating. When plastic coating is added to any item it becomes tear-proof andwaterproof, since the laminating film encapsulates the item completely by being bonded

to both its sides.

Lamination process took 18 hours for the

material of 2000 kg as 1000 kg of printing

material sandwiched with 1000 kg of film of

plastic.Plastic cost per kg is Rs.130 according

to which 1000kg cost 1.3lac.

Laminating Machines: -

The laminating process is quite simple,

although its development was not easy. Laminating machines these days are products of

decades of perfection and refinement, which has resulted in producing two of the most

common types of lamination processes: the Pouch Laminating Machine and the Roll

Laminating Machine.

The machine that we are using currently is Roll Laminating Machine.

Roll Laminating Machine:(Sino Tech Machinery-Taiwan)

This machine can be used to preserve and protect a wide variety of documents between

the sheets of laminating film. These machines are available in a wide range, from those

specially designed for schools to heavy-duty machines used in industrial settings or

commercial purposes. The commercial types of these laminating machines come in many

kinds of format sizes to meet the requirements of in-house graphic departments, business

service centers, print shops, copy shops, and so on. Roll laminating machines meant for

schools can provide a cost effective way of preserving teaching materials and even the

work of students. Designed for flexibility, quality, and convenience, roll laminating

machines have various features like adjustable control of heat, variable control of speed,

adjustable tension, and automatic shut down.


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Slitting Process

Several methods are available for soft materials like plastic films and paper. Razor

blades, straight, or circular blades are being used. Some blades cut through the material

while others crush the material against a hard roll. Those are similar to knives and cut thematerial into narrow strips, which are called coils when being rewound. The cutting

blades can be set to a desired width. Some machines have many blades to increase the

options of cutting widths, others have just a single blade and can be set to a desired

location. The slit material is being rewound on paper or plastic cores on the exit side of

the machine.

The process is used because of its low cost and high precision for mass production. Some

machines have a program that monitors the blades and sharpens the blades often to

maintain the quality and precision of the cut.

Slitting process took 18 hours and after slitting total material of 2000 kg become 1850 kg

as 150 kg of material cut from extreme sides of film.

To understand this process lets take an example of

1850 kg of final product. 1000 kg raw material go for

the printing process and 1000 kg of material include

in the process of lamination then they combine

together like a sandwich and final product that is made after slitting have weight of 1850

kg as 150 kg of material waste in slitting process as result of cutting the edges of film.

After Completion of Final Product:

Transfer to warehouse, which is having a Capacity of 2000 tons.

Total Area of Plant

Total area of plant consist of company is 1000sqft

Area of Machinery ground floor is 700sqft

Area of Machinery first floor is 800sqft

Warehouse consist of 550sqft


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CONCLUSION

After the survey of the company and by the analysis of production process we found outthat their production process is well managed and organized as they have very skilled

employees and labors also they have their plant at ideal location in context of

transportation cost saving as their plant is located near to the port as well as closer to their

major clients also it is very feasible for the workers and other employees like the hospital

is there in case of emergency also the mosque is there and working condition is also good

for employees and worker. These factors increase the productivity of employees and

motivate them towards efficiency. They are very conscious about their quality of printed

material as this is the core value for their business and this unique characteristic

differentiates them from their competitors and thats why they have clients those are

leader in their respective businesses and so the demand is increasing at very high rates

with the passage of time.

Recommendations

We noticed that this kind of process has lots of wastage like if a plastic roll is break down

between the process then it becomes very complicated to restart the process so they

should adopt some very sophisticated method while rolling of the plastic film so they can

avoid the wastage and can save the excess cost.

References:

Mr. Muhammad Hammad Zia (Plant Manager)03212823548

http://encyclopedia2.thefreedictionary.com/

www.granwell.com/bopp/

www.imexbb.com/cpp-film-mcpp-film

www.pneac.org/printprocesses/gravure/

www.buzzle.com/.../laminating-process

www.dictionary30.com/meaning/Slitter

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