FLEXO PRINTING MANUFACTURING FACILITY
[CODE NO.3901]
Flexible packaging refers to any package or part of a package the shape of which can be readily changed. Flexible packaging includes, but is not limited to, bags, pouches, liners, and wraps utilizing paper, plastic, film, aluminum foil, metalized or coated paper or film, or any combination of these materials. Flexible package manufacturers are sometimes referred to as "converters." The word "converted" in this use is an industry-specific term that refers to the fact that flexible packaging materials start out as rolls of paper or foil, or beads of plastic resin, and are "converted" into a package or roll of packaging material.
Flexography is a roll-feed web printing process. Flexographic printing is commonly used to print high volumes of labels and packaging. Presses can print on a variety of films, foils, papers, corrugated board, and paperboard and achieve speeds of 500 to 2000 feet per minute.
In the simplest and most common form, the flexo process consists of below mentioned components 1) Fountain pan / tray , 2) Fountain roll, 3) Doctor blade , 4) ink-metering ( anilox ) roll , 5) plate cylinder and impression cylinder, 6) Impression roll , 7) Substrate These are illustrated in the figure below. 4/17/2018 13 In the simplest and most common form, the flexo process consists of below mentioned components 1) Fountain pan / tray , 2) Fountain roll, 3) Doctor blade , 4) ink-metering ( anilox ) roll , 5) plate cylinder and impression cylinder, 6) Impression roll , 7) Substrate.
Products printed on flexo presses include adhesive and shrink-sleeve labels (bottle wraps); ice cream cartons; folding cartons; shopping bags; plastic bags; pouches; packets; gift wrap; tissue; envelopes; wallpaper; and disposable plates and cups.
Printing on flexible packaging is almost entirely conducted by rotogravure and wide- web flexographic printing. The ratio of rotogravure printing to flexographic printing among converters is approximately 1:4. Flexible packaging printers are likely to be included under SIC codes 2671, 2673, 2674, and 3497. Typical NAICS codes for this industry include 322221, 326112, 322223, 326111, 322224, 322225, and 332999. Flexible package printers could also be classified under other SIC and NAICS codes as well depending on other processes conducted at the facility.
Printing, coating, and laminating may all be performed on or in-line with a flexible package printing press and these activities are included in the source category. One portion of the flexible packaging industry provides fully printed packaging materials (designated "preformed specialty bags") to contract packagers. Another portion provides combination or laminated materials (designated converted wrap) for printing and/or final packing by captive packaging operations. Applying coatings is a major capability of flexible packaging converters, so the same facilities may be used to manufacture non-packaging materials such as gift wraps and hot stamp foils. The industry makes a distinction between labels and wrappers, which are package components, from a product that becomes the entire package and should be called a flexible package. Any printing of shrink-wrap labels or wrappers conducted on or in-line with a flexible package printing press is also considered to be included under the flexible packaging source category. Printing of self-adhesive labels would not be considered flexible packaging.
COST ESTIMATION
Plant Capacity 500000 Pcs /day
Land & Building (600 sq.mt.) US# 92400
Plant & Machinery US# 585000
Working Capital for 2 Months US# 1001208
Total Capital Investment US$ 1748308
Rate of Return 64%
Break Even Point 26%
INTRODUCTION
HISTORY OF FLEXOGRAPHIC PRINTING
CLEAR PACKAGING
TYPES OF PRINTING PROCESSES
OFFSET LITHOGRAPHY
ROTOGRAVURE PRINTING
FLEXOGRAPHIC PRINTING
TYPES OF PRINTING INKS
TYPES OF FLEXOGRAPHIC INKS
CHOICE OF SUBSTRATE IS ALSO ONE OF THE MAIN FACTORS IN INK SELECTION.
SUBSTRATES CAN INCLUDE:
4 COMMON TYPES OF FLEXOGRAPHIC INKS
HERE ARE SOME MORE DETAILS ON THESE TYPES OF INKS, AND WHAT APPLICATIONS THEY'RE BEST FOR:
1. WATER BASED
2. SOLVENT BASED
3. ULTRAVIOLET (UV) AND ELECTRON BEAM (EB)
4. OIL BASED 2
FLEXOGRAPHIC INKS ARE SEPARATED INTO TWO CLASSIFICATIONS: VOLATILE
AND ENERGY CURABLE.
THE UNCOATED FILMS USED FOR UV BASED INK-
FLEXOGRAPHIC INK FOR POLYETHYLENE FILM
UV INK
HOW FLEXO PRINTING WORKS
THE STEPS FOR PREPARING PHOTOPOLYMER PLATES ARE
INKS
SUBSTRATES
FLEXOGRAPHIC INK DELIVERY SYSTEM
PRESS CONFIGURATIONS
COMMON IMPRESSION CYLINDER (CIC) PRESS
STACK PRESS
CORRUGATED PRESS
REPEAT LENGTH
PLATE TYPES
MOLDED RUBBER
PHOTOPOLYMER
LASER ABLATED PLATES
PLATE ELONGATION
DISTORTION
TYPE WEIGHT
DOT GAIN IN FLEXOGRAPHY
PLATE DUROMETER
INKS
WATER-BASE INK
SUBSTRATES
CHEMISTRY OF UV (PHOTOINDUCED) CURING TECHNOLOGY
THE MAIN COMPONENTS OF SUCH FORMULATIONS BASED ON RADICAL
POLYMERIZATIONS ARE:
PROPAGATION
TERMINATION
USES AND APPLICATION
MARKET CATEGORIES
CORRUGATED
FLEXIBLE PACKAGING
GIFT WRAP AND WALLPAPER
FOLDING CARTONS
RIGID PAPER BOXES
ENVELOPES
PAPER GROCERY BAGS
PLASTIC CARRIER BAGS
MILK CARTONS
TAGS AND LABELS
PRE-PRINTED LINERBOARD
APPLICATION AREAS OF UV CURING INKS
PROPERTIES OF MACHINE
ADAVANTAGE & DISADVANTAGE
ADVANTAGE:-
BENEFIT: HIGHLY AUTOMATED
BENEFIT: COST EFFICIENT
BENEFIT: FAST
DISADVANTAGE:-
DRAWBACK: NOT IDEAL FOR SMALLER JOBS
DRAWBACK: SETUP CAN BE TIME CONSUMING
MARKET SURVEY
KEY PLAYERS
FLEXOGRAPHIC PRINTING INKS MARKET, BY APPLICATION
FLEXOGRAPHIC PRINTING INKS MARKET, BY REGION
COMPETITIVE MARKET SHARE
MACHINERY SUPPLIERS
RAW MATERIAL SUPPLIERS
INK
SUBSTRATE
MACHINERY PHOTOGRAPHS
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)