ROTOGRAVURE PRINTED AND LAMINATED POUCHES AND ROLLS (8 COLOUR)
[CODE NO.3404]
Flexible packaging products include candy wrappers, bags for cookies, snack foods, fresh and frozen products, diapers and personal hygiene products, envelopes for powdered soups and juices, flexible bags for ketchup and mayonnaise and for cleaning products such as laundry detergents, labels for beverage bottles, peel-off lids and labels for yogurt containers and wrappers for ice cream products. All of the Company’s products are manufactured in accordance with international requirements and customized to meet individual customer specifications.
Production of flexible packaging products begins in pre-press. The main pre-press process involves the digital design for packaging graphics, including color separation, text and layout. There are two forms of printing: rotogravure and flexography. The rotogravure printing process involves diamond-etching a cylinder for each product’s color layer. It is appropriate for high-quantity orders. Flexographic printing process requires a polymer plate (one for each color) with the design to be printed, that is wrapped around a metallic cylinder.
Traditionally, machinery and equipment requirements for rotogravure printing have been greater than for flexographic printing, and as a result, flexographic printing has been more commonly used. While flexographic printing quality has traditionally been inferior to the rotogravure method in terms of printing clarity and quality, these differences have been diminishing over time as the quality and equipment investments in the flexographic printing method have increased.
Production of flexible packaging products continues by combining the different layers of material(s) required for each particular packaging order; the combination of materials depends on the product’s requirements, such as impermeability, desired shelf life and cost considerations. Flexible packaging products are made from any combination of the following: plastics (such as polypropylene, polyethylene and/or polyester), aluminum foil, paper, wax and adhesives. The most common packaging types are single-layer and multi-layer, coextruded barrier films, doy pack containers and metallized films. Many of the packaging component materials are purchased in film rolls. Due to the high volume of polyethylene used in flexible packaging, this raw material is purchased in pellet form (resin) and extruded at the Company’s facilities into rolls of the appropriate diameter, thickness, width and color for each particular order.
After the printing process, additional laminates and any other necessary layers are attached using adhesives between layers. Finally, the rolls are cut, folded (if necessary) and packaged.
Flexible packaging is the second largest segment in US packaging, accounting for 18% of the industry. It makes sense; this type of product wrap is ubiquitous. Every time you open a bag of chips, squeeze a tube of toothpaste, or get your afternoon caffeine fix from a teabag, you can thank the nearly 79,000 American workers in flexible packaging manufacturing.
The complexity of printing on a flexible substrate is daunting. The sheer variety of materials such as polybags, extruded polyethylene films, overwraps, and rollstock complicate the already challenging process. Schedulers must account for ink changeouts, equipment set-ups, and different cure times. Add to this the normal floor constraints of job deadlines, labor skill-sets needed, and post-processing activities required, and it becomes apparent how much a facility in this industry can improve processes with a robust scheduling tool.
COST ESTIMATION
Plant Capacity : 4.00 Ton/day
land & Building (1000 Sq.Mtr) : Rs. 1.18 Cr
Plant & Machinery : Rs. 1.25 Cr
Working Capital for 1 Month : Rs. 2.12 Cr
Total Capital Investment : Rs. 4.63 Cr
Rate of Return : 30%
Break Even Point : 49%
INTRODUCTION
PROPERTIES
PERMEABILITY RATES OF SELECTIVE PLASTIC PACKAGING MATERIALS
RADIATION STABILITY OF POLYMERS
PHYSICAL PROPERTIES OF PLASTICS USED IN FOOD PACKAGING
CHEMICAL AND PERFORMANCE PROPERTIES OF PLASTICS
USES & APPLICATION OF FLEXIBLE PACKAGING
PROPERTIES AND CHARACTERISTICS
INNOVATIONS AND ADVANCEMENT IN FLEXIBLE PACKAGING
METALIZED FILMS
MODIFIED ATMOSPHERE PACKAGING
ACTIVE PACKAGING
EDIBLE AND SOLUBLE FILMS
INTELLIGENT PACKAGING
OVERVIEW OF FLEXIBLE PACKAGING
PROCESSING OF DIFFERENT TYPES OF FILMS
BLOWN FILM
CAST FILM
COEXTRUSION
ADVANTAGE OF CO-EXTRUDED MULTILAYER FILM
RAW MATERIALS
PROPERTIES AND CHARACTERISTICS OF MULTI LAYER CO-EXTRUDED FILM
5 LAYER FILM
EVOH BASED 5 LAYER FILMS
MOLECULAR STRUCTURE OF EVOH RESINS
PRESERVING FOOD QUALITY
PROTECTING THE ENVIRONMENT
RESISTING INDUSTRIAL CHEMICALS
SUPERIOR GAS AND MOISTURE BARRIER PROPERTIES
BARRIER TO FLAVOUR PERMEATION
BARRIER TO AROMA PERMEATION
RESISTANCE TO SOLVENTS
UV-RESISTANCE
EXCELLENT FLEX-CRACK RESISTANCE
GOOD PRINTABILITY
GAS BARRIER PROPERTIES OF EVOH VS OTHER POLYMERS
HOW PACKAGING HAS CHANGED
MARKET SURVEY
FIGURE: PLASTIC PACKAGING INDUSTRY OUTLOOK (USD BN)
FUTURE DEMAND FOR FLEXIBLE LAMINATES
LAYER FILM
INDIA AS MANUFACTURER BASE FOR GLOBAL MARKET
TOTAL POLYMER CONSUMPTION 2012-13
TOTAL INSTALLED CAPACITY
PRODUCTION OF COEXTRUDED MULTILAYER FILM
GLOBAL MARKET OF FLEXIBLE PACKAGING
FIGURE: SHARE OF PACKAGING MEDIUMS
FIGURE: USE OF POLYMERS IN FLEXIBLE PACKAGING
FLEXIBLE PACKAGING MARKET DYNAMICS
TABLE: NEW PRODUCTS IN FLEXIBLE PACKAGING
CHANGING CONSUMPTION PATTERNS
ADVANTAGE OF FLEXIBLE LAMINATES
KEY DRIVERS OF PACKAGING INDUSTRY
FIGURE: INDIAN RETAIL INDUSTRY OUTLOOK (USD BN)
FIGURE: INDIAN FOOD & BEVERAGE INDUSTRY OUTLOOK (USD BN)
FIGURE: PACKAGED FOOD SPEND (PER CAPITA)
FIGURE: GLOBAL SEGMENT BREAKUP OF PACKAGING MATERIALS (%)
INCREASED FOOD SAFETY, QUALITY & SHELF LIFE:
INNOVATIONS IN PACKAGING:
FIGURE: END-USAGE SHARE OF PLASTIC PRODUCTS (%)
FUTURE OPPORTUNITIES
CONCLUSIONS
MANUFACTURING PROCESS OF FLEXIBLE PACKAGING
PROCESS FLOW DIAGRAM
METHOD OF POUCH MAKING
ROTOGRAVURE PRINTING PROCESS
DETAILS OF ROTOGRAVURE PRINTING
GRAVURE - PRINTING PRESSES
COMPOSITION OF SOLVENTLESS LAMINATOR
DETAILS OF SOLVENT FREE LAMINATING PROCESS
TYPICAL SOLVENT FREE LAMINATOR
TYPICAL SOLVENT FREE METER-MIX
BIO-FILM CONSIDERATIONS DURING SOLVENT FREE LAMINATION
COMPARISON OF LAMINATION PROCESSES
TECHNIQUES OF CO-EXTRUSION
VARIOUS CO-EXTRUDED FILMS:
PLANNING AND SCHEDULING IN FLEXIBLE PACKAGING MANUFACTURE
PLANNING AND SCHEDULING WORKBENCHES
QAD QMS (QUALITY MANAGEMENT SYSTEM)
AUTOMATION SOLUTIONS
ENVIRONMENTAL IMPACT OF FLEXIBLE PACKAGING
SOLVENT USE AND TREATMENT
ENERGY USE
PRINTING
PROCESS LOSSES
BLOWN FILM EXTRUSION PROCESS
SUPPLIERS OF PLANT AND MACHINERY
SOLVENT LESS LAMINATING MACHINE
POUCH MAKING MACHINES
ROTOGRAVURE PRINTING MACHINE
SUPPLIERS OF RAW MATERIALS
ADHESIVE
PRINTING INKS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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