Production Process
A brief glimpse into our line of production
1. PAPER CUTTING PROCESS
Firstly,
the paper roll holder automatically opens up and stands in an up-right position
once it detects that it's empty. Secondly, the paper roll is inserted into the
holder using a clamp-lift. Once this is done the paper roll holder folds back
into a horizontal state while the paper hangs on to it, next the machine is
idle until a certain size is inserted into the touchpad. After this the machine
calculates the amount of time it will take for the roll to be sliced up into
the built-in led of the machine. Once the start button is pushed on the touchpad,
the automated guillotine starts pushing down into the conveyer while the paper
is pushed on the conveyer positioned right under the cutter. This is done
thanks to the paper roll holder spinning in a clockwise rotation for the roll
to open up and guide itself towards the conveyer which then moves it sight
under the guillotine. the cutter is cutting down into the paper with one record
interval, this lets the conveyer and with one second interval, this lets the
conveyer and with one second interval, this lets the conveyer and the roll
stand adjust its speed according to the size that was inserted into the
touchpad. Lastly, there is an intersection right where the conveyer stops and
slides the sheets on to a wooden pallet form where the pallet is picked up by a
fork-lift and taken to the next process in the line of production.
2. PRINTING
Offset printing process
• Plate Preparation: Offset printing uses metal plates (usually aluminum) with a photosensitive emulsion coating. The plates are produced through a process called computer-to-plate (CTP), where digital files are directly transferred to the plates using lasers. • Plate Mounting: The plates are mounted onto the plate cylinders of the offset press. Each plate corresponds to one color (cyan, magenta, yellow, and black, plus any spot colors). • Ink Application: Offset printing uses oil-based or soy-based inks that are applied to the plates. These inks are transferred to a rubber blanket cylinder before being transferred to the printing surface. • Fountain Solution: Simultaneously, a fountain solution (usually a mixture of water and other chemicals) is applied to the non-image areas of the plate. This solution helps to keep the non-image areas clean and receptive to ink repellency. • Offset Printing Unit: The printing process occurs on an offset press, which typically has multiple printing units. Each unit prints one color, and the paper (usually paper) passes through each unit sequentially to build up the final image. • Transfer to Blanket: image from the plate is transferred to a rubber blanket cylinder. The rubber blanket cylinder then transfers the image onto the sheet. • Drying: After printing, the ink needs to dry before handling. This can be achieved through air drying or using infrared or UV lamps for quicker drying. • Finishing Processes: This can include cutting, folding, binding, or other post-printing processes depending on the final product..Flexo printing process
• Ink Mixing: Inks used in flexo printing are typically water-based or solvent-based and are mixed to achieve the desired colors based on the print job requirements. • Anilox Rollers: These are responsible for metering the ink onto the printing plates. Anilox rollers have a specified line screen or cell count that determines the amount of ink deposited. • Substrate Feed: The material to be printed (substrate), such as paper, film, or foil, is fed into the press. • Printing: As the substrate passes through the press, each printing plate transfers ink onto it, one color at a time. Flexo presses can have multiple printing units to apply different colors in a single pass. • Drying/Curing: After each color is applied, the substrate passes through a drying or curing system (often UV or hot air) to set the ink before the next color is applied. • Die Cutting: Once printing is complete, the printed substrate may undergo die cutting to cut it into the desired shape. • Rewinding/Finishing: Finally, the finished product is rewound onto rolls or sheets, ready for further processing or packaging.
3. LAMINATION
Lamination process is carried with high precision and thoroughness as it’s a complex process where each sheet is analyzed for any color contrast in printing that may have an indirect effect on the lamination quality. Firstly, a wooden pallet with printed paper is inserted into a cube-shaped compartment which is located at the far-end side of the machine. Once the paper is inserted, the machine verifies the position and alignment of the paper. When the paper is properly aligned, the machine updates the LED to a green tick on the printed paper compartment. Which brings us to the next step where the laminate film is slid onto the cylindric tube which spins in a clockwise direction that is perfectly timed with the conveyer.As the paper moves along the belt, the laminate film rolls on to the paper. Before this takes place, the laminate moves through another conveyer that puts glue onto the laminate film before being compressed on to the paper. Once the laminate attaches itself onto the paper, the paper moves through a heated compressor which dries up the glue while increasing the stick strength. In the final step,the paper finally goes through the slitting section where the paper conjoined together with the laminate are separated which then directs it onto the wooden pallet.
4. STEAM CORRUGATION (3 PLY)
Firstly, the corrugation machine is turned on and left idle for about 30 to 45 minutes for it to heat up the conveyer. Once this has been done, the paper holders open up and stand in an up-right position, As this is a 3 ply corrugation, the machine consists of 2 paper roll holders. Once paper rolls are inserted, the roll stand folds back into their original state. Before the machine is started, the operator is supposed to insert the size on which the sheets are to be sliced into. After this, the start button is pushed which enables the paper roll holders to spin in a clock-wise direction. The first holder guides the paper to a heated conveyer which intersects with another belt that is moving the paper from the second roll stand. But, before they conjoin with one another the second paper travels to a corrugation roll that consists of cylindrical shaped tubes called ‘flutes’. The paper wraps itself up around the scorching hot corrugation roll that is pressed into the paper to takes its shape. Once this is done the second paper is sprayed with glue, as it’s guided towards the intersection where both the papers conjoin. As the conjoin, a hot streaming metal belt is pushed onto the paper, drying up the glue and sticking them together. Lastly, The paper is guided towards the slitting compartment where they are sliced up into the designated sheet size.
5. AUTOMATED CORRUGATION PLANT (5 PLY)
The Kraft paper is passed through the single facer machine where it is heated and pressed to form the fluted corrugation.
Flame Heating: A flame heating system is sometimes used to achieve the required temperature quickly. The flame helps in the rapid drying and setting of the adhesive as well as the flutes.
Liner Attachment: The corrugated paper is then combined with liner paper using the starch adhesive. For 5-ply corrugation, three layers of corrugated (fluted) paper and two layers of liner paper are used.
Second Single Facer: The process is repeated to create additional corrugated layers.
Double Backer: The combined layers pass through the double backer where the remaining layers are added.
The combined 5-ply corrugated board is then passed through a drying section where it is subjected to controlled heat to ensure proper bonding and curing of the adhesive.
The flame heating may also be used in this section to accelerate the drying process.
The dried and bonded corrugated board is then cut to the required size using rotary cutting machines.
Trimming is done to ensure uniform edges and precise dimensions.
6. AUTOMATED PASTING MACHINE
Firstly, load the printed paper and flute paper onto their respective feeders. Ensure proper alignment and tension.
Next set up the machine parameters, including adhesive type, application rate, roller pressure, and speed. Adjust the settings based on the type of paper and adhesive used.
After this, fill the adhesive reservoir with the appropriate adhesive. Ensure the adhesive is mixed correctly and has the right viscosity.
Once this is done, set up the adhesive application system, including rollers or nozzles, to apply the adhesive uniformly on the flute paper. Ensure the adhesive is spread evenly to ensure strong bonding.
Once all this is taken care of, activate the paper feeders to guide the printed paper and flute paper through the machine. Ensure both papers are fed at the correct speed and aligned properly. Use sensors and guides to maintain the proper alignment of the papers. Adjust as necessary to prevent misalignment or overlapping. Set the pressing rollers to apply the right amount of pressure, ensuring that the printed paper and flute paper are firmly bonded. Adjust the pressure to avoid damaging the paper. Monitor the pasting process continuously, checking for any issues such as adhesive streaks, paper jams, or misalignment.
7. DIE CUTTING
Design Creation: A die (a specialized tool for cutting) is designed according to the desired shape and size of the final product. This design includes cutting lines and creasing lines.
Material Preparation: Corrugated sheets are cut to size, if necessary, to fit the die cutting machine.
Loading:
The corrugated sheets are manually loaded onto the machine's feed table or loading area.
Alignment:
Sheets are manually or automatically aligned to ensure they enter the machine at the correct angle and position.
Die Cutting:
The machine presses the die onto the corrugated sheet, cutting and creasing it simultaneously.
The semi-automatic aspect usually involves manual feeding of the sheets and possibly manual adjustment of the die for each new batch or design.
Ejection and Collection:
The cut sheets are ejected from the machine, where they can be collected manually or through an automated conveyor system.
Waste material, such as the offcuts from around the die-cut shape, is usually manually removed or collected in a waste bin.
Inspection and Finishing:
The cut pieces are inspected for quality. Any necessary finishing touches, such as folding along the creased lines or additional trimming, are done manually.
The final products are stacked and packaged for shipping or further processing.
8. AUTOMATIC ZAY PASTING
The automatic carton Zay pasting process is a specialized system used in the manufacturing of cartons. This process involves the automated application of adhesive to create strong, well-aligned carton structures. Here's a detailed overview of the steps involved:
Carton blanks, which are pre-cut and pre-scored sheets of paperboard, are fed into the machine. This can be done using a feeder system that ensures a continuous supply of blanks.
The machine applies adhesive to specific areas of the carton blanks. The type and amount of adhesive used can vary depending on the requirements of the carton and the adhesive properties. Precision in adhesive application is crucial to ensure strong bonding without excess adhesive.
The machine folds the carton blanks along the pre-scored lines. Automated folding ensures precise alignment of the flaps and sides, which is essential for the structural integrity of the cartons. Sensors and alignment mechanisms help maintain accuracy.
After folding, the adhesive-coated areas are pressed together to form a strong bond. This can involve rollers, belts, or other pressing mechanisms that apply uniform pressure to ensure proper adhesion.
If the adhesive requires curing or drying, the cartons may pass through a drying section where heat or air is applied to set the adhesive. This step ensures that the bond is strong and durable.
Automated quality control systems, such as cameras and sensors, inspect the finished cartons for defects, misalignments, or weak bonds. Any defective cartons are automatically rejected.
The finished cartons are then stacked and prepared for further processing or packaging. Automated systems can organize the cartons into stacks of a specified number, making them easy to handle and transport.
9. QUALITY CHECKING
- Purpose: To check for any visible defects such as tears, creases, or misprints.
- Process: Inspect the carton for uniformity, proper alignment, and overall appearance.
- Purpose: To ensure the carton dimensions are within specified tolerances.
- Process: Measure the length, width, and height using rulers
- or calipers and compare with design specifications.
- Purpose: To measure the edgewise compressive strength of the corrugated board.
- Process: A sample of the board is placed in an edgewise position and pressure is applied until it crushes.
- Purpose: To determine the pressure required to rupture the corrugated board.
- Process: A sample is placed under a rubber diaphragm, and pressure is applied until the sample bursts.
- Purpose: To assess the compressive strength of the entire carton.
- Process: The carton is placed in a compression tester, and pressure is applied until the carton collapses.
- Purpose: To measure the amount of water absorbed by the corrugated board over a specific period.
- Process: A sample is exposed to water for a fixed time, and the amount of water absorbed is measured.
- Purpose: To ensure the moisture content of the board is within acceptable limits.
- Process: Samples are weighed, dried in an oven, and weighed again to calculate moisture content.
