A Training Report

ON

PaharPUR 3P

Department of Printing Technology

GURU JAMBHESHWAR UNIVERSITY OF SCIENCE & TECHNOLOGY

HISAR, HARYANA

Submitted to: Submitted by:

Himanshu Ahuja

Roll No.11032006

B.Tech. (PT)

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ACKNOWLEDGEMENT

Without any hesitation I can say that the training session which I had for period of 6 weeks could

not be complete successfully without the generous assistance of number of people. I have an

obligation to acknowledge these all people who gave valuable cooperation, assistance and

advices to success my training.

I am highly thankful to Mr. Satendra Katiyar, the Deputy Manager of printing department of

PAHARPUR 3P For giving me the opportunity to complete my training in their esteemed

organization.

I am extremely grateful to workers, engineers, and unit heads of Paharpur 3P industry for sharing

their valuable knowledge with me and other trainees.

I take this opportunity to express my gratitude towards Prof. Dharmender Kumar, Chairman,

Department of Printing Technology and Mr. Anjan Kumar Baral. Incharge, Mr. Pankaj

Kumar, Advisor, Training and Placement, Department of Printing Technology for allowing me

to do my training in the PAHARPUR 3P and for their timely help.

I am indebted to the entire teaching staff especially Mr. Ambrish Panday, Lecturer, Dept. Of

Printing Technology ,Mrs. Vandana Gupta and Mr. Arohit Goyat for sharing their knowledge

and experience with me and making the training pleasurable and memorable part of my life.

The final tribute and appreciation are reserved for my family members, my colleagues and my

senior students for the help they gave me in the preparation of this document.

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PREFACE

Industrial training is the boom for the students as they expose the industry and get a chance to study

the working of most modern equipment and the methodology of doing jobs.

For the better understanding of the practical situation in industry, the experience gained from training is vastly important.

It is an extraordinary opportunity to experience practical industrial environment, work discipline, team work, time

management, quality controlling and to obtain a clear understanding of the theoretical knowledge which was gathered at

the university.

I got my training in Paharpur 3P, Which is one of the most renowned industries in the field of

“Gravure” printing and Flexible Packaging.

Factory Manager: - Mr. Manoj Bisht

Deputy Manager: - Mr. Satendra Katiyar

Assistant Manager: - Mr. Raj Kumar Panday

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DECLARATION

I, Himanshu Ahuja student of B.Tech of GURU JAMBHESHWAR UNIVERSITY OF SCIENCE

AND TECHNOLOGY ,Hisar hereby declare that I have completed my Six Weeks Industrial

Training at“ Paharpur 3P “.

It is my original Training Report and the same have not been submitted earlier for any academic

purpose. The information submitted is true and original to best of my knowledge.

(Himanshu Ahuja)

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Introduction

‘What is Gravure Printing?’

Rotogravure printing or just simply gravure printing is a type of intaglio printing process which

uses a rotary printing press. It involves engraving an image onto a copper plated steel cylinder

base.

The first step is to create a cylinder with an engraved image for each color that makes up the

design. The engraving process will create on the cylinder surface the cells that will contain the

ink in order to transfer it to the substrate (film or paper). Since the amount of ink contained in the

cells corresponds to different color intensities on the substrate, the dimensions of the cells must

be carefully set: deeper cells will produce more intensive colors whereas less deep cells will

produce less intensive ones.

A rotogravure printing press has one printing unit for each color, typically CMYK or cyan,

magenta, yellow and key (printing terminology for black), but the number of units varies

depending on what colors are required to produce the final image. There are five basic

components in each color unit: an engraved cylinder (AKA “Gravure cylinder”) whose

circumference can differ according to the layout of the job; an ink fountain or reservoir; a doctor

blade; an impression roller; a dryer.

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‘How does it work?’

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. Acting as a squeegee, the doctor

blade scrapes the cylinder before it makes contact with the substrate, removing excess ink from

the non-printing (non-recessed) areas and leaving in the cells the right amount of ink required:

this tool is located quite close to the substrate so that the ink left in the cells does not have

enough time to dry.

Next, the substrate gets sandwiched between the impression roller and the gravure cylinder: this

is where the ink gets transferred from the recessed cells to the substrate. The purpose of the

impression roller is to apply force, pressing the substrate 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. Then the substrate goes through a dryer because it

must be completely dry before going through the next color unit and absorbing another coat of

ink.

Image Generation.

4 Color PROCESS Printing / CMYK

The image is separated into 4 different color values

Cyan / Magenta / Yellow / Black

Individual colors are printed as dots at varying densities Individual dots combine to form

additional unique colors

In Packaging printing, 4 color process is typically combined with line colors to accurately

represent trademarks and logos and to maintain color consistency over large areas of solid

colors

The number of final colors in a design is nearly limitless

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Characteristics of Gravure Publication Printing

The simplicity of the process helps make Gravure the fastest of the printing processes, the web

runs at the greatest speed. The stability of the press makes it possible to print very wide webs.

Gravure Printing suffers less downtime, and there is less wastage in comparison to other printing

process. The combination of speed, width, and low downtime produces very high productivity

and compensates for the relatively high cost of preparing a cylinder. The cost of preparing a

cylinder is obviously less important on long runs and better print quality. The combinations of

speed, width, & low downtime have big/ volume publication produced to look as alternate for

their processes.

Advantages:

high quality over long print runs

inline process possible

100 % seamless printing

excellent design reproduction

high quality of halftone image and gradation

excellent quality with metallic ink

combination of solvent and water-based ink

Suitable for various qualities of board / paper / foil.

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About “Paharpur 3P”

The Origin

In the late 80\'s and early 90\'s, the flexible packaging in industry was evolving and was driven

by the lubricant and tobacco industries. Paharpur 3P was the brainchild of Mahendra Swarup

(Founder Chairman of the group) who was looking for a sunrise sector and seeing the

opportunity and the growth rates (35- 40 percent annually) in the industry, decided to diversify

into flexible packaging with a start-up unit in Sahibabad Industrial Area. That is how Paharpur

3P originated in the year 1994, with a green field project having modern state of the art

technology imported from Europe. Since then Paharpur 3P has come a long way under the

visionary leadership of Gaurav Swarup, Chairman of the company.

Plant Preview

Paharpur 3P is situated on an 18 acres plot on Delhi – Uttar Pradesh border wherein 33 percent

of the area is utilized for corporate office and manufacturing / storage facilities. And the balance

area is maintained under green cover reflecting the group\'s penchant for environmental safety

and beauty.

Company uses natural ventilators for air circulation in plant and storage areas and makes

effective use of natural light. Rain water harvesting system has been put in place and ground

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water levels and quality of ground water are measured through PIZO meters. The water

discharged from cylinder making department is treated through effluent treatment plant and is re-

used for irrigation.

The manufacturing operations for flexible packaging in the plant includes pre-press, plating,

cylinder engraving, printing, lamination, extrusion coating, slitting, blown film plant, pouch

making, bag making and ink making.

Paharpur follows the ISO 9001: 2000-Quality Management System and the ISO 22000: 2005-

Food Safety Management System. It also complies with the requirements of Occupational Health

and Safety Management System - OHSAS: 18001.

Presence - National & International

“Paharpur 3P caters only to the organized sector of the Indian market,” says Anand. And how

does the company define the unorganized sector? “Well, products like Pan Masala, Gutkha fall in

that sector,” explains Anand. “The high ethical standards of our group restrict us from dealing in

those products,” he adds.

For Paharpur 3P, the buyers in the organized sector are major FMCG companies like Unilever,

Nestle, Cadbury, Pepsi, Britannia, Heinz, HLL, ITC, Dabur, Mother Dairy, JK, MRF, SKF,

Asian Paints, Heinz, Bayer, Tata Tea, Eveready, Parry, Britannia, Sara Lee, Novartis, Henkel,

Perfetti and others. The company is in the premier category of manufacturers of Flexible

Packaging and rated among the top five players in this field.

The company has its marketing branches in Mumbai, Delhi, Bangalore, Kolkata, Chennai and

Hyderabad.

Paharpur 3P is present in SAARC countries, Middle East, Africa and Europe. As far as imports

are concerned for the blown film plant, granules are imported from renowned suppliers like

Dow, Exxon Mobil and Ampacet.

Future Focus

The future plans of Paharpur 3P include increasing the plant capacity from the present 7,000 MT

to 12,000 MT per annum. That will also involve addition of new equipment at several stages of

production.

The company has been acquiring technologies from abroad as also equipment to meet its goal of

moving up the profitable value added chain.

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The company has another unit in Chennai that caters to the needs of customers in the southern

region like Hindustan Lever Ltd (HLL).

On the technology front, the company has tied up with Perfotec of the Netherlands to provide

competitive solutions for fresh produce.

The company is working closely with technology leader in polymers, US-based Dow Chemicals

and Toyo – a leader in food grade packaging inks.

The Recognitions

Paharpur 3P has always been recognized by its customers for its innovative ideas, product,

quality, service and new developments. The company has several awards and recognitions to its

credit like the Indiastar Awards, Asia star Awards, WordStar Awards, PFFCA Star Awards, Best

HR Practices Award and the Eco-Friendly Company Award. Today 70% of products are

manufactured for food applications where we are committed to provide safe and hygienic

packaging for the food industry.

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Various departments in Paharpur 3P

Cylinder Preparation

Printing

Lamination

Slitting

Pouch Making

Blown Film

Quality control Department

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Cylinder Preparation

All gravure cylinders are produced on site using a dedicated fully automatic engraving and

chroming line, which features two Max Daetwyler Gravostar 850 engraving heads.

The GS 850 packaging engraver is a value-oriented unit, which includes a layout workstation, an

engraver driver station and an engraver. It has a high frequency engraving head capable of

engraving screens at up to 175 l/cm. As well as features such as telescopic enclosures, automatic

lifting and lowering of the engraving head to prevent damage to the engraving head diamonds

and on-board diagnostics the GS 850 also offers Daetwyler's Vista cell sensing system.

The Vista system is used for head calibration and cell correction. Cells are measured on the fly,

cell widths compared with the required widths and corrections made until the engraved cell is the

right size. The system has a video monitor so that the user can see what the Vista camera sees

and an optional printer that will output hard copy prints of the final cells for quality control

purposes.

Fully integrated, in-house, engraving facility to utilizing rotogravure cylinders .This gives an

edge in replicating the designer’s idea flawlessly on the substrate, consistently, timely while

ensuring utmost confidentiality.

Machine use a diamond stylus to cut cells. Each cell creates one printing dot later in the process.

They are fully computer-controlled and the whole process of cylinder-making is fully automated.

Today Paharpur 3P have the capacity to engrave in excess of 9000 cylinder per annum.

Web-fed gravure printing requires a gapless gravure cylinder, onto which the image is applied

directly, by means of etching or engraving. For this, the cylinder must be prepared in a costly

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mechanical and galvanic process. In its basic design, the gravure cylinder consists of a thick-

walled steel tube with flanged steel journals. To increase the stiffness of this hollow cylinder,

some of the cylinder journals are drawn inwards and are supported inside the tube on additional

steel discs. All of these joints are welded during the manufacture of the gravure cylinder so that a

solid roller body is created, which still has to be balanced so that there are no vibrations when

running at high speed (typically up to 15 m/s) in the printing press.

The cylinder receives a base copper layer on its surface, which, among other things, serves to

achieve the specified diameter of the finished gravure cylinder.

For the application of another copper layer, which varies from print job to print job, there are

several methods that are described in the following sections (note: the top copper layer is twice

as hard (Vickers hardness approximately HV 200) as the base copper, so that this copper layer

has good cutting properties as regards the electromechanical engraving process):

The base copper layer is coated with an engravable copper layer (approximately 80 μm) in an

electroplating process as shown in the figure above. This thin layer only allows a one-time

engraving. The advantage of the thin layer technique is that all the gravure cylinders of one type

have the same diameter dimensions and less mechanical surface treatment is required after the

electroplating process than with thick layer processes (see be low). The removal of the en-

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graving (after dechroming) is achieved by dressing or milling the copper. After this, a new

copper layer is applied. (In the special process known as copper recycling, the copper layer is

removed in an electroplating reversal process. In this process, an additional nickel barrier layer

of approximately 25 μm between the base copper and engraving copper is necessary.) The thin

layer technique is used in some 35% of cases, whereby the copper recycling method only

accounts for some 5%.

The process sequence for preparing an engraving cylinder is generally as follows:

• removing the used gravure cylinder from the gravure printing press;

• washing the gravure cylinder to remove residual ink;

• removing the chrome layer;

• removing the copper image-carrying layer, either chemically, by means of electroplating, or mechanically;

• preparing the copper plating process (degreasing and deoxidizing, applying the barrier layer if the Ballard skin method was employed);

• electroplating;

• surface finishing with a high-speed rotary diamond milling head and/or with a burnishing stone or a polishing band;

• Etching or engraving (producing the image on the gravure cylinder);

• test printing (proof print);

• correcting the cylinder, minus or plus (i.e., reducing or increasing the volume of cells);

• preparing the chrome-plating process (degreasing and deoxidizing, preheating, and – if

necessary – sometimes polishing);

• Chrome-plating;

• Surface-finishing with a fine burnishing stone or abrasive paper;

• storing the finished cylinder or installing it directly in the gravure printing press.

Electromechanical Engraving (As Done In Paharpur 3P)

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The operations involved in electromechanical engraving are significantly shorter compared to the

etching process. Nowadays, they are normally controlled directly with the data recorded in

prepress. In this way the mounting of a scanning original on a separate scanning drum that runs

synchronously with the engraving machine is also no longer needed. Hence, the engraving

machine only consists of a lathe- like device, into which the prepared gravure cylinder is

mounted. The engraving procedure is similar to a rotating cutting process, but the cut is

intermittent (stylus frequency).

The gravure cylinder rotates during engraving at a constant surface speed (depending on the

screen at approximately 1 m/s).At the same time the diamond stylus of the engraving head mo ves

at a high frequency (4–8 kHz). The diamond penetrates the copper at different depths and

produces the cell.

The cells are equidistant from each other in the circumferential direction (direction of engraving)

due to the continuous circumferential velocity and the engraving frequency. Engraving of

neighboring tracks is semi-staggered. The lateral repeat length corresponds to the forward

motion of the engraving head per cylinder revolution in the shaft direction of the gravure

cylinder.

Depending on the width of the web to be printed, up to sixteen engraving heads (typically eight)

with styli are used for publication gravure printing. The burrs on the copper surface are usually

removed by a scraper which is fixed to the engraving head during the engraving process. The

cylinder must therefore only be lightly polished before it is used for a test print in a proofing

press, corrected manually in accordance with this, and then finally chrome-plated.

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Printing Department

Printing lines are equipped with the most modern facilities such as auto-registration controllers,

viscosity controllers and are capable of in-line cold seal specialty coatings. Department

Comprises of two High speed Machines.

Rotogravure Press FR300 Shaanxi Beiren Printing

Machinery Co., Ltd.

Main Features

1. Double-working position disc-type Unwinder/Rewinder at high stable performance and the

machine has the humanism design; new-type safe chuck assures the operators safety; unwinding

cutter can complete up cutting or down cutting.

2. Indeed is at precise double-tension control.

3. Low-damping chill roller with good cooling effect prevents the web from being damaged at

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high- speed machine performance.

4. Centralized lubricant system at dosing greasing makes the guide roller high-speed and flexible

performance.

5. Direct pressing mechanism makes the web performance without distortion, which can improve

register accuracy and reduce the waste.

6. New-type environment protection and energy-saving drying system controls the residual

impregnate efficiently.

7. Movable ink tray carriage shortens the auxiliary time and improves the productivity.

8. Straight-line cutter makes not only obverse/reverse cutting but also clearance-rewinding, and

the rewinding reel is very tidy.

9. MMI touch screen and vector varispeed control system have the good performances

Technical Parameters

Max web width 520-1220 ㎜

Print speed 250m/min、300m/min

Register accuracy ≤±0.10 ㎜

Unwind/rewind dia. Ф1000㎜

Plate cylinder diameter Ф420 ㎜-Ф940 ㎜

Drying method oil heating

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ROTOMEC ROTOPAK 3000 -3R

Synthetic roller:-

Synthetic Roller used for impression has hardness of about 65 to 75 shore.

Number of colors 9

Web width (mm) 520-1220mm

Print repeat range (mm) 400-920

Drying specifications 1-8 printing units double drying; 2 to 8 Single Drying .

Drying heat source Oil

Unwinder type Auto splicing

Max reel diameter Unwinder (mm) 1000

Rewinder type Auto splicing

Max reel diameter reminder (mm) 1000

Video camera Web video “Super Handy Scan 4000″ from BST (2011)

Register control Quadtech

Viscosity control Eltromat

Corona treatment Vetaphone treatment CP3/10kw

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Dent can also due to synthetic roller on the poly as in dent in the rubber or synthetic will come on

different area on the poly but not side movement of that only up and down movement. As dent on

gravure cylinder will occur at that same place and same position.

• Defect can also occur due to oversized rubber roller in which ink from outside of gravure cylinder

comes on that impression or rubber roller and then ink from that roller comes on the poly film which

we are printing.

• So always rubber roller of size equal to poly width and lesser than gravure cylinder length is used.

• Misprint can also occur due imbalance of rubber roller as if a layer of ink keep on getting on that and

in the end the thickness of that ink layer become more than the thickness of poly film we are printing

so due to which rubber roller get imbalanced so at one end that roller is raised at one end due to

which at some area we get print and at some not or lighten.

• Diameter or circumference and length of the gravure cylinder are variable as according to the size of

image along length or width we can say.

• Here in Paharpur 3P gravure cylinder used are of same in length and circum but of different circum.

• Both cylinder and blanket cylinder moves at equal speed.

Here mainly electronic engraved cylinder with chromium plating is used.

• Doctor blade :-

• In this, it is made up of steel and is generally adjusted at an angle of 55 degree +- 5degree.

• Thickness of the doctor blade is about 0.15mm.

• Width of the doctor blade is about 45mm.

• The adjustment of doctor blade is done by keeping the blade just sharp edge above supporter and

pressing from one to other so that air filled between blade and supporter can be removed and then by

holding both blade and supporter we tight down it.

• Lamella: - It is the sharper edge of blade and its dimension is like this1.4/0.070mm here 1.4mm is

length of that sharp edge and 0.070mm is thickness of that sharper edge.

• DRYER: - This is the kind of system used for drying any applied chemical to polyfilm.

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Dryers’ temperature for printed matter is kept approximately 37 degree Celsius.

For adhesive drying it is kept around74 to 76 degree Celsius.

• Pre-make ready operations :-

• Cleaning of the cylinder and blanket cylinder.

• Centering of the gravure cylinder.

• Web feeding and also tension control is done.

• Doctor blade adjustment is also done.

• Assembly plate is also adjusted according to the color gravure cylinder is in which unit placed.

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Lamination Department

At Paharpur 3P -lamination facilities include:

Solvent based lamination

Solvent less lamination

Extrusion lamination

Water Based Lamination

NORD MECCANICA - Super Simplex SL

Technical Specifications Other Specifications

Laminating materials BOPP 12-80 my

PP CAST 20-150 my ALU 7-40 my

LDPE-LLDPE 20-200 my

Coex 25-200 my NYLON CAST 20-80 my

Petp 8-30 my OPA 12-18 my

PAPER 40-150 g/m2

Type of laminator: Solventless

Working width: 1315 mm

Unwinder diameter: 1000 mm

Rewinder diameter: 1000 mm

Mechanical speed: 400 m/min

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LAMINATOR NORDMECANICA-SUPER-COMBI

2000

Manufacturer NORDMECCANICA

Model SUPER COMBI 2000

Year 2001

Application Duplex lamination

Type of lamination/coating

COMBI – SOLVENTLESS AND SOLVENT /WATER BASED

Working width (mm) 1300

Speed 300 m/min

First Unwinder type Single shaft less

Max diameter reel Unwinder

1000

Secondary Unwinder

type Single shaft less

Max diameter reel

Unwinder 1000

Rewinder type Single shaft less

Max diameter reel 1000

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Rewinder

Coating unit with interchangeable trolley; available 2 trolleys 1- Rotogravure trolley

for solvent and water based glue 2- Solvent less trolley

Drying 6M long drying tunnel; 2 independent hoods; 4 fans

pumping mixing unit 2 components solvent less

Coating rollers Approx. 15 rubber rolls

Additional information 3 temperature regulation units; cold seal unit. In running conditions

Laminated materials /secondary) Coated materials (primary):

BOPP 12–80µm;

PETP 10–30µm;

LDPE-LLDPE 60–20µm (solvent based);

LDPE, LLDPE 30–200µm (solvent less);

OPA 12–10µm;

NYLON CAST 50–80µm (solvent based);

NYLON CAST 30–80µm (solvent less);

ALU 9–40µm (solvent based);

ALU 12–40µm (solvent less);

PP CAST 60–150µm;

CALANDERED PAPER 40–300g/m2

(solvent less only).

BOPP 12–80µm;

PP CAST 20–150µm;

ALU 7–40µm;

LDPE, LLDPE 20–200µm;

DIFFERENT COEXTRUDED

MATERIALS 25–200µm;

NYLON CAST 20–80µm;

PETP 8–30µm;

OPA 12–18µm;

CALANDERED PAPER 40–300g/m2.

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Tandem Co-Extrusion Lamination coating Machine

Place of Origin: Guangdong, China (Mainland)

Brand Name: Huilong

Model Number: EXC

Voltage: 220v, 380v, 415v

Power (W): 220-300kw

Dimension (L*W*H): 23m*12m*5m

Work Chart-

1. Unwind

2. Corona Treatment

3. Water Based Adhesive

4. 16micron Poly. (In Melted Form) + 10 Micron Matt applied via different rollers with applied

Heat and Pressure.

5. Rewinding.

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Specifications of Machine

Extrusion Lamination Machine

1.EXC1350/ (90+90+90)-F-4 tandem co-extrusion

2. Thickness auto-control

3.Rewind auto-splicing

Technical parameter: Product structure: laminating on single side 5 layers for one time: main

materials/extrusion layer A/sandwich layer materials/co-extrusion layers B-C.

Extruder: 3 sets HL-90 dynamic extruder, two of them formed into one HL-90S co-extrusion

machine which use special-made extrusion laminating screw and feed block. Motor power is

37kw.

Extrusion: maximum 200kg/h for single machine.

Coating thickness: single layer T-die: 12-50μm; co-extrusion T-die: 12-60μm. (Single layer

thickness is 6-50μm.)

Production speed: maximum 150m/min.

Specification: 1200mm,1350mm,1450mm,1700mm.

Effective width: maximum 1100mm,1250mm,1350mm,1600mm.

Base materials: BOPP, BOPET, BOPA, Paper (50-200g/).

Sandwich materials: CPE, CPP, MCPP, MPET, Al-foil, Paper.

Used resins: coating resin such as LDPE, LLDPE, PP, EVA, EAA, EMA, EMAA etc.

Unwinder diameter: maximum 800mm or 1000mm.

Rewinder diameter: maximum 800mm or 1000mm.

Tension control: automatic tension control, maximum tension is 40kg.

Electrical control mode: operated by MMI, extrusion thickness automatically controlled by

computer, the whole machine is in linkage control state.

Workshop requirement: Length 23m×Width 12m×Height 5m.

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Slitting Department

Slitting Department consists of 6 High Speed Hi-Tech machines, which are –

NUZEN S-737

Mechanical Speed 450 Meter/Min**

Max. Web width 1300 mm & up to 1600 mm*

Max. Parent Reel Dia 1100 mm

Parent Core I.D. 3” (76mm) & 6”(152mm) Combi chucks

Max. Rewind Reel Dia 600 mm & Up to 800 mm*

Max. Rewind Reel Weight 225 Kg.(Shaft)

Min. Slit Width 50 mm

Rewind Core I.D. 3”(76mm) & 6”(152mm)*

Core Material Cardboard, Paper & PVC

Max. Trim Width 5mm to 20 mm

Web Guider Axial Motion +/- 50 mm / (+/- 100 mm)*

Type of Slitting:

Razor Cutter (Cut in Air & Cut in Groove)* Shear Cut (Rotary Knives)*

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MACHINES FEATURES:

Unwind Section:

Shaft less unwind section

Combi chucks 3” (76mm) / 6” (152mm)

Ground Floor Pick up

Auto Self-centering

Automatic programmable tension control

Ultrasonic diameter sensor (for automatic diameter stop)

Digital Web Guiding System (Line/Edge/Contrast/Broken Lines)

Alignment roller

Guide/Idler rollers

Driven Bow (Banana) roller

Driven Unwinder*

Safety curtains at unwind*

Tension Isolation Section:

Servo Driven Pull/Draw roller (for accurate Length Stop) (Length Counter)

‘S-Wrap’ tension isolator

Slitting Section:

Cantilevered designed shaft for quick and easy changeover

Razor Cutter (Cut in Air & Cut in Groove), Shear Cut (rotary cutter)*

Safety Guards for knives

Trimming removal/suction blower with Venturi

Rewind Section:

Differential ball shaft technology

Automatic programmable tension control

Pneumatically controlled adjustable lay on (Linear Motion Technology)

Pneumatically controlled contact arms

Lay on Web clamp bar*

Programmable taper tension control

Servo Drive (for accurate Length Stop) (Length Counter)

Ultrasonic diameter sensor (for Automatic Diameter Stop)

Reel Ejector/Reel Removing System/Reel Thruster*

Pneumatic Swiveling type Take off arms (Reel Unloading Stand)

Safety Scanners at rewind*

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Star Slit

Technical Data

Star Slit Conslit

General: Materials to be processed:

Plastic films made from PE, PP, PA, PET, PVC, Paper, and Laminates,

Working width:

57, 69" 40, 57, 69, 80"

Machine speed:

2,000 fpm 2,600 fpm

Drive side:

on the right side, seen in material running direction Unwinder:

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Parent roll diameter:

40" 40" or 51"

Options:

hydraulic roll lifting in device

Slitting Section:

Slitting width:

starting from 2" (50 mm) (optional 1" (25 mm))

Slitting system:

scissor cut, razor blade cut

Rewind:

Finished roll diameter:

Max. 24" Max. 32"

Finished roll cores:

3" and 6" I.D. (with corresponding accessories)

Lay on rolls:

full width contact rolls

Winding tension:

Max. 650 N Max. 650 N

Options (depending on model):

Eccentric contact roll

Air expanding shafts

Auto push off for finished rolls

Laser core guides

Motorized roll tree

Close loop feedback Auto or manual aid for shear knife positioning

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Titan ER610 compact slitter

It is available in 2 web widths – 1350 & 1650 mm (53 & 65 INS) – with a maximum rewind

diameter of 610 mm (24”). It also features a 10” touch screen control system and an integral

edge-trim extraction system. The pneumatically controlled braking system provides accurate

web tension control and a digital edge-guide system controls lateral movement of the unwind

reel to +/- 50 mm (2”). Slitting systems available include shear knives, rotary razor (burst) or

razor slitting in air or groove. Optional features include a static electricity control system, laser

(line) core positioning, EU safety guarding, and laser safety scanners and unwind roll loading

trolley.

The Titan ER610 slitter will process a wide range of flexible materials including plain, printed,

coated or metalized film from 20 to 200 micron, a wide range of laminates and paper from 30 to

200 Gsm

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DCM - Panthere 4

PANTHERE is a slitter-Rewinder well known to many converters all over the world. It is highly

appreciated for its rewinding capacity of 800 mm diameters, its easy adjustment and the quality

of its production. This is due to accurate tension control and cutting precision.

EQUIPMENT :

- Built- in or separate Unwinder

- Unwinder with or without shaft

- Razor and rotary cutter cutting station

- Rewinding on air shafts or friction shafts

- Digital Pilot touch screen control

- Appropriate unloading system

CHARACTERISTICS :

- Width: 800 to 1600 mm

- Diameter at Unwinder: 1000 or 1300 mm

- Diameter at reminders: 2 x 800 mm

- Minimum cut: 20 mm

- Production speed: 600 m/min

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Pouching Department

Pouching Department consists of 12 Pouch making machines of GALAXY PACKTECH IND.

LTD. Of which 9 are “High Speed Bottom Fold & 3 Side Seal Pouch Making Machine”

and 3 are “Automatic High Speed standup & zipper Pouch Making Machine (GS-

20)”. This department also includes two “Automatic Pouch Spout Inserter”.

High Speed Bottom Fold & 3 Side Seal Pouch Making

Machine

This model can make double up folded & three side seal pouch.

This model can make different length pouch on same time.

In built Cooling Technology provides leak proof product at high operating speed.

Pouch length variation minimized to zero by servo driven Laminate Pulling

Mechanism.

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Technical Specification

Pouch Size Three Side Seal

(W x L in mm) Folded Side Seal

Pouch

(W x L in mm)

Min. 75 x 75 Min. 75 x 75

Max. 300 x

300

Max. 300 x 300

Linear Speed * 22 Mtr./Min.

Roll Diameter

Main Unwind

(mm) Min. 125

Max. 600

Secondary Unwind

(mm) Min. 125

Max. 600

Roll Width Main Unwind (mm)

Max. 600

Secondary Unwind (mm)

Max. 600

Elect. Power

Consumption**

Max 10 KW. 3 ph, 415 V (A.C.), 50

Hz.

Prime Movers Servo Motor : 11 N-M / 2000 RPM Main Motor 3 Hp / 1440 RPM, 3 Ph.

Air

Consumption*** 8 CFM, 6 Bar Pressure (Water Contain less than 0.01%)

Water

Consumption

10-12 Ltr. / min., 8-12°C at 2 Bar

Pressure.

Operational speed depends upon Laminate Thickness, Composition and Pouch Size. Electrical Power Consumption depends upon application of machine.

Air Consumption depends upon optional attachments.

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Automatic High Speed standup & zipper Pouch

Making Machine (GS-20) ( Waterline)

GS Series Advantage

The technology Ensures Excellent Pouch Seam even with High micron laminates.

In built Water Cooling Technology provides leak proof product at high operating

speed.

Stand up pouches from same laminate roll provides competitive advantage to end

user.

Pouch length variation minimized to Zero by servo driven Laminate Pulling

Mechanism.

Technical Specification

Pouch

Size Stand Up (W x L x G in

mm) Three Side Seal (W x L in

MM) Zip Pouch

(W x L in MM)

1

Line

Min 60 x 150 x

30 1 Line

Min 150 x 160 1

Line

Min 60 x 150

Max 500 x 500 Max 250 x

500

Max 250 x 500 x

100 2 Line

Min 75 x 60 2

Line

Min 60 x 75

Max 250 x 500 Max 250 x

250

2

Line Min 60 x 70 x 30 3 Line Min 50 x 60

3

Line

Min 60 x

50

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Max 160x 500 Max 250 x

160

Max 250 x 150 x

100 4 Line

Min 50 x 60 4

Line

Min 60 x

50

Max 125 x 500 Max 250 x

125

Linear

Speed * Upto 20 Mtr. / Min. Upto 22 Mtr. / Min.

Upto 20 Mtr. / Min.

Roll

Width

Main Unwind (mm) Bottom Unwind

(mm) Min. 300 Min. 60

Max. 1000 Max. 200

Roll Diameter

Main Unwind (mm) Bottom

Unwind (mm) Max. 600 Max. 500

Optional

Attachment

Front & Back Eye mark Servo Synchronization

Both Side Gusset Synchronization Same Roll Stand Up Pouch Former & Gusset Assembly

D- Punch / Star Punch / Butterfly Punch etc.

Secondary Film Roll unwinding Unit (1000mm)

Elect. Power

Consumption

Max. 35 KW, 3 ph, 415 (A.C.), 50 Hz

Prime Power

Servo motor: 26 N-M / 2000- RPM Main motor 5 Hp / 1440 RPM, 3 Ph.

Unwind Motor (4 Nos.) 1 HP, 1440 RPM 220V AC , each 3 Ph.

Air

Consumption

8 CFM, 6 Bar Pressure (Water Contain less than 0.01 %)

Water

Consumption

10 – 15 Ltr. / Min. 8-12 C at 2 Bar

Pressure.

Operational Speed depends upon Laminate Thickness, Composition and Pouch Size

Electrical Power Consumption depends upon application of machine Air Consumption depends upon optional attachments

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Name: NCA1620-30 Automatic Pouch Spout Inserter

Model NCA1620-30

Pouch size L×W（120-320）×（100-250）mm MAX: 300×250mm 320×200mm

Cutting angle 17°-45°

Spout type Short spout

Capacity 30-35pieces/min

Power AC 380V, 50HZ, 3P, 4.0KW

Compressed air 0.5Mpa 250NL/min

Cooling water 6L/min

Dimension L×W×H 35000×1800×1950mm

Weight 1800Kg

Main Technique Features:

● Angle of the spout-welding can be adjusted from 17°to 45°, the angle-cutting and the spout-

welding can be done at the same time.

● Max size of pouch can be 2200ml. (Special order is needed for the over size)

● Clear display, PLC control, easy operation.

● Double servo pouch supply guarantees the accurate position.

● Spout preheat and reduce the hot sealing temperature.

● Multi-hot sealing, cold sealing, ensure the sealing strength.

● Trouble alarm display.

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QUALITY CONTROL DEPARTMENT

• TENSILE STRENGTH MACHINE - There are three types of tests are done that are:-

Seal strength

First of all in this strip of poly or substrate of about 1.5cmor 15mm in width we cut down.

After this we fold that strip along the length wise.

Than we seal folded mouth or end of that strip with pressure heating machine and we get

sealed strip.

Now we put that strip with open mouth or end upper end of it in upper mouth and then

another end in the down holding mouth.

In the end we start the machine in which downward mouth will towards down till that we

seal breaks we note down the reading.

In this way we get seal strength and we can change according to that.

Operating Range- NS 40 to IT 500.

Pneumatic operated cylinders with individual solenoid valve.

Specially designed heaters & reputed electrical system.

Machine working capacity- approx. 300 batteries per 8 hour shift.

Electricity Required- 7 KW, 3 Phases, and 415 V- AC, @ 50 Hz.

Machine Weight- app. 700 kg., Size- 5’L X 6’ b X 7’ h

Air Required- 3-4 c.f.m. @ 7kg/cm2 Operating temperature range is 350oc to

38Ooc

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Tensile strength or Elongation strength:-

We have to measure the elongation or tensile strength along machine direction as well as cross

direction

In this type we measure the elongation strength or stretch till poly or substrate breaks.

First of all we take a strip of width 2.5 cm or 25 mm and 10 cm or 100 mm in length

After that fixing it into both ends of the machine and then stretched until it breaks and in

this we note down the distance and load it can acquire or tolerate

The unit of both the test is calculated in manpower means force/area.

We also measure the adhesive strength of the poly films we use to adhere with each

other.

This is done by splitting both layers of poly films.

Drop test or Dart impart test - it is also known as bursting strength.

In this test we measure out that how much pressure or load it can hold if any substance poly

pouch gets dropped from certain height.

First of all the substrate is tightened on hollow cylinder with some air pressure and then after

tightening again pressure of about 490mm Hg is applied to hold it tightly.

Than pendulum of some weight is set at the height of 66 cm and dropped from there.

We check it out whether the poly gets burst or not.

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GSM and micron measuring machine

"LINUX" GSM TESTER - Electronic Model

The equipment is designed to measure/determine GSM of Paper, paperboard, fabric, PVC,

plastic and other materials. It measures 5 different sample sizes viz., 5x5cm, 10x10cm,

10x20cm, 20x20cm and 25x25cm. It displays Gsm of samples cut selected to size on a digital

indicator. Has printer port facility for printing and data transfer. The equipment comprises of an

electronic scale of 125 Gsm capacities and least count of 0.01 gm and templates. Two

templates are supplied with the equipment and other sizes are available on request.

There are two types of polyfilm are measured:-

• Printed

• Non printed

• Printed poly film:-

First of all we cut out the sample

• For printed poly films, first of all we measure the GSM of the printed substrate or poly film

sample.

• Then we split out coated film and remove the ink from printed substrate or poly film with ethyl

acetate or toluene properly.

41

• After that we measure the GSM of both the film and then we find out the difference of both the

poly films (printed and cleaned).

• In the end we can measure out that GSM of the ink layer on the sample.

We can also measure the adhesive layer applied between poly films which are laminated by same

way as for printed we does.

Non printed poly film:-

• We cut out the poly film or substrate of size about 10*20cm and then we measure out the GSM of

that piece.

• Than we divide that value by 2.

• After that we multiply it with 100.

• In this way we measure out the GSM of the substrate and we can know uniformity of poly films.

WE CAN ALSO MEASURE MICRON OR THICKNESS OF THE POLYFILM BY DIVIDING

THE GSM OF THE POLYFILM BY DENSITY OF THAT POLYFIM ONLY.

MICRON = GSM / DENSITY

• For poly tube type poly film we measure just GSM simply along width 20 cm.

• For different poly films we measure GSM separately along the width to cover the whole poly.

• GSM unit is in gm

• 38 to 42 dyne charge is given on the polyfilm through corona discharge method.

Friction tester machine:-

• In this we measure both static and dynamic friction of poly films.

• In this we just keep the wide strip of poly with treated side up and then we keep some solid slab on

it.

• Than that solid slab is moved on that strip.

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• Reading which comes on that meter we note it down.

• The purpose of the friction testing is check whether more or less force to be applied to move the poly

film to be printed for e.g. if there is more friction in the poly then it will not move to required or vary

speed so in this way it will not properly printed or laminated or slitted or if coefficient of friction is

less than required it will not be controlled over the rollers as it will slide more than required.

• Treated and non treated both side are checked as treated side is checked so that when we keep each

poly on each other should not slip for e.g. lamination needed two layers on each other and to cut it

properly so that it moves under rollers properly, non treated side is checked for filling material in it.

• Here only we take dynamic friction of more concerned as in printing movable is there more

important rather than static friction we don’t take so much.

• Its unit is in Newton/meter *meter.

Opacity testing machine:-

This is the machine used for measuring the amount of light is getting transmitted through poly film.

• In this, we take a strip of poly and put in frame and then light is passed, then we note the percentage

of opacity.

• In this it is measured in percentage.

Treatment test:-

In this test, we check out which is the treated side, meaning on which side of poly film we had

increased the surface energy or charge.

• We take strip of adhesive tape and adhere to both the side of poly and pluck off then.

• And on which side it makes less noise than it is treated side.

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Puncture Resistance Tester

The Puncture Resistance Tester is used for determining the puncture resistance of corrugated

board by measuring the energy required to puncture it. Interchangeable weights supplied to cover

four energy ranges i.e. in new meter 0-5, 0-10, 0-20 & 0-36.

Applications

Testing equipment

Paper industry

Packaging industries.

Electronic Box Compression Tester

It has single push button operation which activates an automatic test cycle, machine starts in fast

speed, detects the box, changes to standard test speed & performs compression test. Overload

protection. Acceptable and non acceptable limit set.

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Applications

Testing equipment

Paper industry

Packaging industries

Universal Oven

forced air circulation by quiet air

turbine, adjustable in 10 % steps adjustment of pre-heated fresh air

admixture by air flap control in 10 % steps

vent connection with restrictor flap

adaptive multifunctional digital PID-microprocessor controller with high-

definition TFT-color display self-diagnostics for fault analysis 1 Pt100 sensor DIN class A in 4-

wire-circuit

45

RAW MATERIALS USED EXTENSIVELY IN

PAHARPUR 3P

INKS As we know that any packaging that is not hard and bends slightly while still holding a shape. It can be a

bag, envelope or pouch that when filled changes shape. Liquid inks used for printing of these flexible

packages with Gravure Process, Called Flexible Packaging Liquid Inks.

High quality inks of various prestigious companies like ”Sakata” and “DIC” are used In Paharpur 3P

LightFastness

Rub

Ink

Properties

Rub Scuff

H2O2

Heat

/Freeze

46

Types of Inks, Their Uses and Properties.

Vinyl Based

Benefits:

High color strength

Good bond strengths

Almost instant adhesion

Low solvent retention

Reliable, high performance results

Free from migrating plasticizer resins.

Use:- High Mileage Jobs.

PU Based

Benefits:

High color strength

Low solvent retention

Prints on wide range of plastic films

Reliable, high performance results

Does not contain pigments based on heavy metals.

Use:- Used in All Types Of Jobs.

Acrylic Based

Acrylic Inks are optimally pigmented and low viscosity inks, for Gravure Printing, high quality

reverse printing applications – directed at Shrink PVC film applications.

Special Features:

Optimal strength

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High HR properties

Good Printing Stability

Good Blocking resistance

Excellent adhesion on PVC films

Good scuff resistance & slip properties

Polyamide Based

Inks are highly pigmented inks, for high quality Surface printing

Special Features:

Good Printing Stability

High gloss

Good Blocking resistance

Excellent adhesion on various filmic substrates

Good scuff resistance & slip properties

Use:- Used for High Quality Surface Printing

NC based

TRUMET FOIL Inks are for Gravure Printing

Special Features:

Excellent adhesion

Excellent HR

Low odor

Good scuff resistance & slip properties

Use:- Mostly used in Food Packaging

48

Substrates

• Polyester (pet) or polyethylene terephthalate:-

BoPET (Biaxially-oriented polyethylene terephthalate), known in the industry as polyester (PET) is a versatile

film used in many flexible packaging applications including lamination. Available in either corona or

chemically treated options for print and conversion. Melior Film Converters also offer a heat sealable PET

film for flow wrap or lidding film applications.

The properties that make PET film ideal for packaging applications include:

High strength for high speed processes, higher tensions, and higher temperatures

Chemical surface treatment during manufacturing or post-manufacturing to enhance

characteristics, such as barrier, adhesion, printability, metal adhesion, and release

High clarity Strength and resistance to tear

Dimensional stability over a very wide range of temperatures and humidity

Resistance to attack by moisture and most common solvents

Excellent barrier to both oxygen and water vapor to extend shelf- life

It is a condensation polymer

Its density is about 1.40.

Its thickness is from 12micron to 15 micron.

Its temperature after printing for drying is 60degree to 70degree.

Only reverse printing can be done on the polyester.

Types of Polyester used in Paharpur and their Applications.

Type Of PET Application

Corona Treated Normal Bond Jobs

Chemically Coated High Bond

Acrylic Oil Jobs

Alox High Stanlization Jobs

Max Barrear High Retort ( Stanlization Jobs )

49

Biaxially oriented polypropylene (BOPP)

When polypropylene film is extruded and stretched in both the machine direction and across

machine direction it is called biaxially oriented polypropylene. Biaxial orientation increases

strength and clarity.[13] BOPP is widely used as a packaging material for packaging products

such as snack foods, fresh produce and confectionery. It is easy to coat, print and laminate to

give the required appearance and properties for use as a packaging material. This process is

normally called converting. It is normally produced in large rolls which are slit on slitting

machines into smaller rolls for use on packaging machines.

Mostly used in Packaging of Biscuits, Snacks and chips.

White BOPP

For food and confectionery packaging

Suitable for single ply or lamination applications

Suitable for VFFS and HFFS packaging applications

Both sides heat sealable

One side (external) corona treated for conversion

Excellent ink adhesion for flexographic and rotogravure process

High whiteness and gloss

Used in Product Labels.

BON Biaxially Oriented Nylon

Biaxially Oriented Nylon film, also known as BOPA film, is made of polyamide resin, which can be used

for a wide range of applications especially where high barrier requirements to gas, fat and transmission of

aroma are necessary. High resistance to impact punctures and pin holing.

Mostly used in OIL jobs like Sundrop due to Puncture Resistance.

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Polyethylene

Polyethylene is the most produced plastic in the world, with which everyone daily comes into contact.

Polyethylene can be processed into soft and flexible as well as into tough, hard and strong products. It can be

found in articles of all kind of dimensions, from the simplest to the most complex shapes. It is used in

everyday appliances, packaging, pipes and toys.

Three main types

By making polyethylene more or less "dense” in the factory, there is a suitable type of material

available for every application. In practice one of the following types is used in 90% of the

applications.

LDPE: "low density” polyethylene

the oldest type. A soft, tough and flexible polyethylene type, used for strong, flexible consumer

items, like screw caps and lids. For a long time already, it is also used as insulation material. At

present the most popular application is foil, from which carrier bags, packaging material and

agricultural plastic are made. During the high water levels in Holland in the last years, the tough

strong LDPE foil served as an improvised reinforcement for the dikes.

HDPE: "high density” polyethylene

this is the sturdiest and most inflexible type. Its sturdy and somewhat tough character can be

used for a large range of applications. For example the well-known gft-container and a number

of everyday domestic products like bottles, clothes pegs and the handle of washing-up brush.

Although HDPE is quite heavy, it can also be used for paper-thin foil that is extremely light and

feels crispy. All of us use this type of foil daily; examples are sandwich bags, pedal bin bags or

packaging for vegetables, fruit or meats.

LLDPE: a mixture of both previous-mentioned types

with this polyethylene one can go into every direction. It has some features from both of the

previous-mentioned types. Both flexible and sturdy products are made from it. LLDPE is

generally used in mixtures with one of the previously mentioned materials. Amongst others, even

thinner foils can be produced. It is also used for multi- layer packaging. LLDPE is extremely

tough and inflexible. These features can be used for the production of larger items, like covers,

storage bins and some types of containers.

51

Solvents Used

Ethyl acetate

Its density is 0.89.

It is used as solvent to maintain the viscosity of the ink.

It is also used to clean the printed ink from poly in quality dept. to check the GSM of printed

poly.

It is used in reverse printing.

Toluene

density is about 0.87.

It is used to maintain viscosity.

It is used for surface printing.

Methyl Isobutyl Ketone (MIBK)

Physical Properties

Molecular weight 100.16

Boiling point 117.4°C

Vapor pressure 16 Torr at 20°C

Freezing point -84°C

Isopropyl Alcohol (IPA)

Molecular weight 60.09

Boiling point 82.26°C

Vapor pressure 32.4 Torr at 20°C

52