press, impressively! now and future of gravure, flexo · pdf fileflexible packaging ......
TRANSCRIPT
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
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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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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