DESIGN AND FABRICATION OF PAD PRINTING

MACHINE FOR FINISHED PAPER PRODUCTS

A PROJECT REPORT

Submitted by

NAVNEET KUMAR MISRA 71606114077

PREM KUMAR.M 71606114086
SUHAIL MUHAMMAD 71606114104
SURAJ.S 71606114106

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

PARK COLLEGE OF ENGINEERING AND TECHNOLOGY,

COIMBATORE-641659

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2010

1
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “ PAD PRINTING MACHINE FOR

FINISHED PAPER PRODUCTS” is the bonafide work of NAVNEET
KUMAR MISRA, PREM KUMAR.M, SUHAIL MUHAMMAD, SURAJ.S
who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Prof.S.PARANJOTHI B.E, M.Sc. (Engg) Prof. R. GOVINDANKUTTY M.Tech (IITM)

SUPERVISOR

HEAD OF THE DEPARTMENT PROF. & VICE PRINCIPAL

DEAN OF MECHANICAL ENGINEERING

Dept. of Mechanical Engineering Dept. of Mechanical Engineering

Park College of Engineering & Technology Park College of Engineering & Technology

Kaniyur, NH 47, Coimbatore-641659 Kaniyur, NH 47, Coimbatore-641659

INTERNAL EXAMINER EXTERNAL EXAMINER

2
 ACKNOWLEDGEMENT

At the foremost we prostrate before the almighty GOD and

praise his honour, glory and pay our contribution of thankfulness
to him for blessing we with all knowledge required us for doing
this successful project.

We thank our chairman Dr. P.V.RAVI, Chief Executive

Officer Ms. ANUSHA R. MAHESH, B.E, M.S (US) and Executive Officer
Mr. T.NITHYANANDAM, B.E, MS (Res), MBA, MISTE who helped us
indirectly to know what engineering deals with and also we extend hearty
thanks to our Principal Dr. G.MOHAN KUMAR, M.E, PhD, MBA,
PGDMRM, MIE, MISTE who provided us with all the facilities to accomplish
this project in college premises itself.

We wish to express our deep sense of gratitude to our Vice

Principal, Dean and our Supervisor Prof. R.GOVINDAN
KUTTY, B.Sc. (Engg), MTech (IITM) for his valuable support
for providing us for all the facilities required to build up this
project work.

We express our gratefulness to our head of the department

Prof. S.PARANJOTHI, B.E, M.Sc (Engg) for his incredible advice in the
completion of this project. We also express our thanks to our project
coordinator Mr. K.S.SATHISH KUMAR, B.E, M.S (Res), MBA (HR),
MISTE for providing us with the necessary details about the project and its
proper schedule.

Finally we thank all the faculty members of mechanical dept for their
cooperation and insistence.

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TABLE OF CONTENTS

4
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO

ABSTRACT 8

LIST OF TABLE 10

LIST OF FIGURES 12

LIST OF SYMBOLS 14

1. INTRODUCTION 16

2. LITERATURE SURVEY 18

COMPANY PROFILE 21

3. DESCRIPTION OF COMPONENTS

3.1 Compressor 27
3.2 Pneumatic Cylinder 28
3.3 Printing pads 29
3.4 Substrate 31
3.5 Ink cup 32
3.6 Printing ink 33
3.7 Image plate and print plate making 34

4. DESIGN CALCULATIONS 45

5
 FIGURES

Fig.1 :Manual Pad Printing machine. 18

Fig.2 :Pad Printed Products. 19

Fig 3 : A single acting compressor. 27

Fig 4 :A reciprocating Compressor. 28
Fig 5 : Double acting Pneumatic Cylinder. 28
Fig 6 :Printing pads. 31
Fig 7 :Paper Plate. 32
Fig 8 : Medicine capsule box 32
Fig 9: New Generation Closed ink cup. 33
Fig 10: Image Plates. 34
Fig 11: Laser printing plate maker. 35

5. WORKING PRINCIPLE 50

5.1 Working
5.2 Features of pad printing

6. ADVANTAGES AND DISADVANTAGES 52

6.1 Advantages
6.2 Limitations
7. APPLICATIONS 56

8. COST ESTIMATION 58

9. CONCLUSION 60

6
10. REFERENCES 62

ABSTRACT

7
 ABSTRACT

In our day today life its quite common that we are using lots of products which
are made attractive and informative through textual and pictorial impressions
made by pad printing. But out of its all scopes, the printing on the finished
paper products was still untouched at a gross level. Here forth, we came up with
an idea for the same and started the project on the “DESIGN AND
FABRICATION OF PAD PRINTING MACHINE FOR FINISHED
PAPER PRODUCTS”.

Pad printing is used for printing on various substrates like Plastics, Metals,
Glass and Ceramics, Paper and Cardboard, Leather. But it is primary used in
places where the printing area is small and / or the contour or surface of the
object is not flat or hard to reach by other printing process. We tried to give
emphasis on the pad printing on the finished paper products which is quite yet
not achieved so easily at larger scales.

We achieved the pad printing on the finished paper products with a minimum
operating pressure of 5 bar and by utilizing pneumatic and electrical systems.
The machine is being developed for a paper products manufacturing company at
Coimbatore.
It is a fully automated machine working with the help of pneumatic cylinders
for its horizontal and vertical movements. The sealed ink cup, silicon printing
pad and an etching plate are the major components of our pad printing machine.
Our project has the current applications in the company itself being developed
for and for its flexibility and efficient working.

8
LIST OF TABLES

9
 LIST OF TABLES

S.NO PRACTICALS PAGE NO

1 COST ESTIMATION 66

10
LIST OF FIGURES

11
LIST OF FIGURES:

S.NO PARTICULARS PAGE NO

1. Rubber Pad Holder 38

2. Guide Rod 39

3. Top Plate 40

4. Print Head Front View 41

5. 3D View 42

6. 3D Wire Frame 43

7. Pneumatic Circuit 44

12
LIST OF SYMBOLS

13
LIST OF SYMBOLS:

P= Working Pressure in N/mm2

D= Diameter of barrel in mm
T= Thickness in mm
Pd = Direct load
Ft1=Hoop stress
Ft2 =Longitudinal stress
p= Pitch (mm)
σy=yield stress

14
 INTRODUCTION

CHAPTER 1

INTRODUCTION:

15
Pad printing is used for printing on various substrates like Plastics, Metals,
Glass and Ceramics, Paper and Cardboard, Leather. But it is primary used in
places where the printing area is small and or the contour or surface of the
object is not flat or hard to reach by other printing process.

Pad Printing is finding increasing favour in a host of commercial and

industrial applications.

Any way you look at it, Pad Printing is an unlikely imaging process. It
"borrows" a unique amalgamation of features from gravure, screen printing and
rubber stamp printing, yet its most frequent industrial decorating competitor is
none of these processes. Instead, Pad Printing most often encroaches on jobs
once dominated by Hot Stamping. Even the process itself is somewhat
befuddling. If the ink is so attracted by the silicone pad that it leaves the
recessed areas of the printing plate, why does it abandon the pad so completely
upon touching the substrate? Unlikely as it may be however; this process is
finding increasing favour in a host of commercial and industrial applications.

It is adaptable to a variety of shapes and contours on parts with a variation in the

surface, yet fine detail and precise copy can be achieved. Four color processes is
obtained with exact registration. Pad printing is ideal for decorating toys, plastic
house wares, and injection molded components. This technology also lends
itself to marking electronic components such as resistors, canisters, and
connectors. Any part, plastic, ceramic, or metal can be production marked by
this process. The equipment can be semi or fully automated, yet remains a low
capital expenditure technology.

16
 LITERATURE SURVEY

CHAPTER 2
LITERATURE SURVEY:

17
Pad Printing is a printing process that can transfer a 2-D image onto a 3-D
object. This is accomplished using an indirect offset (gravure) printing process
that involves an image being transferred from the printing plate (cliché) via a
silicone pad onto a substrate (surface to be printed). Pad printing is used for
printing on otherwise impossible products in many industries including medical,
automotive, promotional, apparel, electronics, appliances, sports equipment and
toys. It can also be used to deposit functional materials such as conductive
inks, adhesives, dyes and lubricants.

Fig.1 Manual Pad Printing machine

Physical changes within the ink film both on the cliché and on the pad allow it
leave the etched image area in favour of adhering to the pad, and to
subsequently release from the pad in favour of adhering to the substrate
(material being printed).

18
The unique properties of the silicone pad enable it to pick the image up from a
flat plane and transfer it to a variety of surface (i.e. flat, cylindrical, spherical,
compound angles, textures, concave surfaces, convex surfaces).

In the early 1960’s the pad printing machines were manually operated type,
which are like shown in fig below. Later only the hydraulic, pneumatic and
Electrical drive system types of machines were manufactured. After that in the
recent years highly automated machines were developed.

Fig.2 Pad Printed Products

19
COMPANY PROFILE

20
 COMPANY PROFILE

K.U.Sodalamuthu
Founder

Creative thinking and an innate sense of observation are vital ingredients for
any successful business venture. The Late Mr. K.U.Sodalamuthu had them in
him when he observed the potential in Paper Conversion Machinery. He chose
an uncommon industry which was largely related to a common one - Textiles. It
is a laudable fact that an innovative brand of industry has its origin in a city
popularly known as "Manchester of South India".
The Brand - Sodaltech holds an amazing 96% of the Indian Market for its paper
Conversion Machinery. The Company has more than 500 installations to its
credit worldwide, with 36.5% of the international market.
The Industry has continued to climb the ladder of success steadily over the past
37 years. The three sons of the founder have been actively involved in the
Company's remarkable success. The eldest Son Mr.K.S.Viswanathan handles
the Production Department .The second son Mr.K.S.Subramaniam is
responsible for the Marketing while the third son Mr.K.S.Balamurugan takes
care of the Administration. Sodaltech has maintained its tempo throughout
21
meeting the challenges thrown out by the rapidly advancing technology, head
on.
New enhancements are a permanent part of the show based on research and
surveys. Rich in experience and always on the lookout for challenge, Sodaltech
is a versatile brand which can meet any form of requirement adapting itself to
different levels of economy and technology.

Paper Cone Production Line

Automatic Paper Cone Making Machine
Partially Automatic Paper Cone Making Plant
Paper Cone Flocking Machine
Automatic Paper Cone Finishing Machine
Paper Tube and Core Production Line
Pulp Moulding Plant
Edge Protector Production Line
Paper Core Polishing Machine
Paper Core Shredding Machine
Parallel Tube Winder
Baling Press
Paper Traffic Safety Cones
Rebuilt Machines
Automatic Core Cutter
High Speed Core Winder with Multi-Cutter
Fiber Drum Making Machine

22
Contact Information
We have a country wide network of sales and service offices all over India to
enable our valued customers to reach us easily.
Our Head Office and Factory Unit # 1:
K. U. SODALAMUTHU AND CO. PVT. LTD.,
# 428 Mettupalayam Road,
Coimbatore - 641 043.
Tamilnadu, India.
Phones: + 91-422-2438346,
+ 91-422-2441223,
+ 91-422-2441805.
Fax : + 91-422-2431279
E- Mail: sales@sodaltech.com

23
Our Factory Unit # 2:
K. U. SODALAMUTHU AND CO. PVT. LTD.,
SF # 73 /1 - A, Solavampalayam Post,
Kinathukadavu - 642 109.
Coimbatore District
Tamilnadu - India
Phone: +91-4259-242383, 241417, 200462

PRE & AFTER SALES OFFICES IN INDIA LOCATED AT

• NEW DELHI
• MUMBAI
• KOLKATA
• CHENNAI
OVERSEAS PRE & AFTER SALES OFFICES IN

UNITED
USA RUSSIA BANGLADESH
KINGDOM

SOUTH
MALAYSIA SYRIA SPAIN
AFRICA

SAUDI
TURKEY BRASIL ITALY
ARABIA

KUWAIT IRAN

24
We have a market share of 96.5% in India and 36% worldwide in paper
conversion machinery. More than 500 of our machinery and plants have been
manufactured and supplied to various parts of India and abroad. Hence, it is not
surprising that accolades and awards have been coming our way for more than a
decade now. In recognition of this performance we have been awarded the

• EEPC (Engineering export Promotion Council) awards for Export

Excellence,
• The Indian Institute of Packaging PACMACHINE awards for
Excellence in Packaging Machinery Design for SODALTECH
Composite Can Making Plant, SODALTECH Spiral Paper Tube Plant,
SODALTECH Fiber Drum Making Plant, SODALTECH Automatic
Paper Cone Plant and SODALTECH Paper Tube / Composite Container
Making Plants.

Our machinery and plants have been exported to several countries

including Mexico, Brazil, Finland, Turkey, Nigeria, Kenya, Zambia, Ghana,

Russia, Sudan, South Africa, Egypt, Iran, Saudi Arabia, Kuwait, Syria, Sri
Lanka, Bangladesh, Thailand, Singapore, Malaysia, Libya, Lebanon, United
Arab Emirates etc.

25
DESCRIPTION OF PARTS

CHAPTER 3
26
DESCRIPTION OF PARTS:

The project consists by following parts:

• Compressor
• Pneumatic Cylinder
• Printing pads
• Substrate
• Ink cup
• Printing ink
• Image plate and print plate making

The pneumatic cylinder and piston arrangement holds the Printing pad. The
compressor provides highly pressurized air to the cylinder. The power will be
transmitted to the piston rod and the printing pad is actuated. Thus the pad is
absorbing ink in shape of art made on the cliché and due to reciprocating motion
of the horizontal cylinder it spreads the print on the substrate.
3.1COMPRESSORS
RECIPROCATING COMPRESSOR

Fig 3: A single acting compressor

27
 A reciprocating compressor or piston compressor is a positive-
displacement compressor that uses pistons driven by a crankshaft to deliver
gases at high pressure.
The intake gas enters the suction manifold, then flows into the compression
cylinder where it gets compressed by a piston driven in a reciprocating motion
via a crankshaft, and is then discharged. We can categorize reciprocating
compressors into many types and for many applications. Primarily, it is used in
a great many industries, including oil refineries, gas pipelines, chemical plants,
natural gas processing plants and refrigeration plants. One specialty application
is the blowing of plastic bottles made of Polyethylene Terephthalate (PET).

Fig 4: Reciprocating Compressors

3.2 PNEUMATIC PISTON CYLINDER:

Fig 5: Double acting Pneumatic cylinder

28
 Pneumatic cylinders (sometimes known as air cylinders) are mechanical
devices which produce force, often in combination with movement, and are
powered by compressed gas (typically air).

Double acting cylinders

Double Acting Cylinders (DAC) use the force of air to move in both extends
and retract strokes. They have two ports to allow air in, one for outstroke and one for
in stroke. To perform their function, pneumatic cylinders impart a force by
converting the potential energy of compressed gas into kinetic energy.

Operations:
General
Once actuated, compressed air enters into the tube at one end of the
piston and, hence, imparts force on the piston. Consequently, the piston
becomes displaced (moved) by the compressed air expanding in an attempt to
reach atmospheric pressure.

3.3 PRINTING PADS:

Pads are three dimensional objects typically molded of silicone rubber. They
function as a transfer vehicle, picking up ink from the printing plate, and
transferring it to the part (substrate). They vary in shape and durometer
depending on the application.

There are three main shape groups: "round pads", long narrow pads called "bar
pads", and miscellaneous shapes (square, rectangular, etc.) called "loaf pads".
Within each group there are three size categories: small, medium, and large size
pads. It is also possible to engineer custom-shaped pads to meet special
application requirements.

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CHARACTERISTICS & PAD CHOICE:
The pad is made with special silicone rubber with the following
characteristics:
• Excellent absorption and detachment of the ink; perfect transposal of the

image to be printed.
• Tear strength and resistance to solvents and inks; pad long life.

• Hardness and form stability; possibility of being used several times.

• Easy to be cleaned; quick maintenance.

The choice of the pad depends on many elements, including the following:
Shape of the printing surface: flat or uneven.
Dimension of the printing surface: printing area.
Type of printing surface: smooth, rough, etc.
Number of the colors to be printed.
These elements determine the pad's size, shape and hardness, expressed in
durometer. Our pads are available in durometer ranges between 10 and 75.
Important:
The size of the pad depends on the printing surface.
It is necessary to use pads whose dimensions are at least 20% greater than
the printing area.
The data of the pads listed in this catalogue refer to the max printing possibility.

• Cylindrical Pads
• Square & Rectangular Pads
• Linear Pads
• Special & Compound Pads

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 Fig 6: Printing pads

3.4 SUBSTRATE:
Substrate is the technical name used to address any parts or materials to be
printed, and it is critical to match substrates and ink series as to their chemical
compatibility. Please consult the substrate compatibility chart for proper ink
selection. Typically you will need a "fixture" to hold and support your substrate
in order to ensure good quality printing. Fixtures vary in materials and
complexity depending on the application.

One of the most interesting examples of fixture making creativity is the use of
Lego for short run printing. This began in a eureka moment of inspiration when
Cliff Rowell, a small print shop owner and grandfather in Calgary, Canada, was
playing with his grandson. This innovation has begun making its way through
the industry in recent years and saves the time and expense of building job
specific custom fixtures. Note that substrates need to be clean and free from
surface contamination to allow proper ink adhesion.

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 Fig 7: Paper Plate Fig 8: Medicine capsule box
3.5 INK CUP:
Open inkwell system (older technology)

Open ink well systems use a trough (ink well) for the ink supply, located behind
the printing plate. A flood bar pushes a pool of ink over the plate, and a doctor
blade removes the ink from the plate surface, leaving ink on the etched artwork
area ready for the pad to pick up.

Sealed ink cup system (latest technology)

Sealed ink cup systems employ a sealed container (ink cup), which acts as the
ink supply, flood bar and doctor blade all in one. A ceramic ring with a highly
polished working edge provides the seal against the printing plate.

ToughCup has a proprietary micro-surface coating designed to repel inks and

solvents. This low-tension surface provides complete release of inks and
drastically simplifies cleaning. It improves productivity by reducing changeover
time when switching colors.
ToughCup is ideal for people who use 2-component inks as there is a good
chance you will be able to clean the cup even if the ink and hardener mix is
accidentally left in it for an extended period of time.
Because of the unique coating, this ink cup is also more resistant to attacks from
solvents, to pigment abrasion and mechanical wear. It is Tough! The ink cup is
also environmentally friendly: it significantly reduces the use of solvents needed
for cleaning.

32
 Fig 9: New Generation Closed ink cup

3.6 PRINTING INK:

Ink is used to mark or decorate parts. It comes in different chemical families to

match the type of material to be printed (please consult the substrate
compatibility chart for selection).Pad printing inks are "solvent-based" and
require mixing with additives at the time of use. UV inks will not fully cure
until UV light hits the ink. UV curable ink can be wiped off many substrates
when mistakes are made. They can be cured with UV light in as fast as 1 second
of light exposure.

This depends on the ink, substrate and the light power and spectrum. UV inks
can be reused as the pot life can be high as long as the ink stays clean, blocked
from UV light and hasn't broken down from sitting. Also there are heat curable
inks too, which work in much the same way as UV in the sense that there is a
"trigger" for curing at your convenience. Two part inks usually have a pot life of
only a few hours or so. They must be disposed of when they cannot be revived
(by means of retarders etc..) Ink choices are available in many convenient and
time savings forms, but for some substrates you will have to use the type of ink
that best adheres to the surface.

33
Climatic conditions will significantly affect the performance of any pad printing
ink, especially the open ink well style printers. Too dry conditions can lead to
faster evaporation of solvents causing the ink to thicken prematurely and too
much moisture can lead to ink issues of "clumping" or something alike. Also the
climate can affect other aspects of the printing process such as ink pick up and
release from the plate to the pad to the substrate, as well as polymer plate to
blade chattering or binding due to humidity. Keep this in mind when planning
the location of your pad printer. Use any necessary heater, air conditioner, and
humidifier or dehumidifier as needed. Always consult Federal, State and local
regulations regarding proper handling, storage and disposal of inks.

3.7 PRINTING PLATE MAKING:

3.7.1 Image plate

Image plates are used to contain the desired artwork "image" etched in its
surface. Their function is to hold ink in this etched cavity, allowing the pad to
pick up this ink as a film in the shape of the artwork, which is then transferred
to the substrate.

Fig 10: Image Plates

34
There are two main types of printing plate materials: photopolymer and steel.
Photopolymer plates are the most popular, providing a good do-it-yourself
option. These are typically used in short to medium production runs. Steel plates
come in two choices: thin steel for medium to long runs, and thick steel for very
long runs. Both steel plate types are generally processed by the plate supplier as
it involves the use of specialized equipment.

3.7.2Printing plate making:

There are two main techniques used to create a printing plate. The traditional
technique requires a UV exposure unit and involves photo exposure with film
positives and chemical etching of a photopolymer plate. A second technique
known as "computer to plate" requires a laser engraver and involves laser
etching of a specialized polymer plate. Although the latter technique is
convenient for short run printing it does have several disadvantages over the
former.

Laser plate making is a process that requires the use of a very soft, low quality
polymer coated plate. Thus, the standard cycle life that can be expected out of a
laser etched plate is quite low (10,000 impressions on the high end). By
comparison, a hardened steel plate can easily last for over 1 million
impressions.

Fig 11: Laser printing plate maker

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Ink cups Now introduces the revolutionary Cobalt 250 laser etching and plate
making system to its lineup of laser engraving machines – a lower cost
alternative to the highly successful Cobalt 1000 laser etcher. The Cobalt 250
laser uses CO2 laser technology and specially designed Imperial Printing Plates
(Patent Pending) to produce high resolution pad printing plates directly from the
computer, without the use of film positives.
The Cobalt 250 laser etcher is an extremely simple and powerful laser
engraving machine system to operate. Just add the Cobalt software to your
standard PC and begin “printing” images to the Cobalt 250 laser. Within
minutes you can etch high resolution pad printing plates without the use of
chemicals, films or concern about depth control. The XY motion of the laser
prints head enables etching of very large images (up to 8” x 12”) making the
Cobalt 250 a highly flexible machine for both engraving Imperial pad printing
plates as well as promotional products.

36
FIGURES

2-D VIEWS

37
38
39
40
41
3-D LABELLED VIEW

42
3-D WIREFRAME VIEW

43
PNEUMATIC CIRCUIT DIAGRAM

44
 DESIGNING CALCULATIONS

DESIGN SPECIFICATIONS:

45
  No of color = 1
 Cup type ( closed cup ) = 60mm
 Image Plate size = 100 X150 mm
 carriage movement = 300mm

 Pad piston stroke on plate = 50mm

 Pad piston stroke on product = 50mm

 Power required = 230V, 50/60Hz, Single Phase

 Power consumption = 20W
 Controller : PLC(Applicable)

 Plc voltage = 24V DC

 Drive system : pneumatic
 Operating pressure = 5 bar
 Air consumption = 60 lit/min

CYLINDER DESIGN:
Cylinder:1
Diameter of cylinder = 50mm
Stroke of cylinder = 50mm
Operating Pressure = 5 kgf/(cm^2)
Cylinder :2
Diameter of cylinder = 50mm
Stroke of cylinder = 300mm
Operating Pressure = 5 kgf/(cm^2)
Maximum operating pressure = 13.5 kgf/(cm^2)
Total load = Pressure * Area
=13.5*(3.14/4)*(5^2)
= 264.93 kgf
= 2649N

46
Printing Force = Operating pr * Area
= 5 * (3.14/4)* (5^2)
= 981 N
GUIDE ROD DESIGN:
Diameter of rod = 20mm
Length of rod = 250mm

Material selected is C 25

Yield stress for C 25 = 280 kgf/(mm^2)

Printing force acting = 981N

Self wt acting = 400N

Stress = load/area
= (981+ 400)/((3.14/4)*(20^2))
= 4.395N/(mm^2)
= 0.439kgf/(mm^2)
Stress created is less than the allowable yield stress.
Therefore, material selected is c 25 with diameter 20mm.

DESIGN OF NUT AND BOLT:

Longitudinal and Hoop stress:

Ft2 = p*d/4*t
Where,
P = working Pressure = 0.5 N/(mm^2)
d = Diameter of barrel = 50mm
t = thickness of barrel = 1.2mm

47
Maximum allowable tensile strength for brass = 280 N/(mm^2)

Hoop Stress = Ft1 = p*d/2*t

= 0.5*50/2*(1.2)
= 10.416 N/(mm^2)
Longitudinal stress = Ft2 = p*d/4*t
= 0.5*50/4*(1.2)
= 5.208N/(mm^2)

Both loop & longitudinal stress are less than the allowable stress.
Therefore, the selected cyilnder and piston is safe under working condition.

Force on piston = Pressure*Area

= 5.208*3.14*(50^2)
= 40906N
This force is Shared or Divided by the 4 nuts and bolts.
Therefore, Force shared by each bolt = 10226.53N

Area of core = Ac = (60*Pb/σy)^(2/3)

= (60*10226.53/280)^(2/3)
= 168.7 mm^2
From PSG design data book Pg.no 5.42 ,for Ac = 168.7 mm^2
Fine Series M16*1.5 can be selected

Pitch = 1.5 mm
Major diameter of Nut = 16 mm
Minor diameter of nut = 14.376 mm
Minor diameter of Bolt = 14.16 mm
Depth of thread = 0.920 mm
48
WORKING PRINCIPLE

49
5.1 WORKING PRINCIPLE:

WHAT DOES THE PROCESS REQUIRE?

• Artwork i.e. the image that is to be printed. Because Pad Printing is often
used for its ability to print very fine detail Artwork can be quite
specialized.
• A film positive, which is produced from the artwork.
• A printing plate, which is either a "plastic" or steel printing plate, referred
to as a cliché. Onto this cliché we have etched an image (from the film
positive) into the surface. So the image is said to be in relief rather than in
profile as in letterpress printing.
• A Pad Printing machine to facilitate the inking and doctoring of the
image, the pick up of the image from the cliché and the put down of the
image onto the item being printed.
• A Tampon or Pad, which is moulded from silicone rubber.
• Specialist Pad printing ink

50
5.2 FEATURES OF PAD PRINTING:

Following are the unique features of the Pad Printing process.

• Can print on convex, concave, curved, recessed and discontinuous

surfaces allowing product designers a substantially broader range of
shapes and designs.
• Pad printing is able to print shapes and surface structures well outside the
capabilities of Screen Printing and Hot Stamping opening up a way to
decorate a whole new range of products.
• Allows wet-on-wet multicolour printing (without intermediate drying) on
non-absorbent surfaces - therefore much reduced down time.
• Is capable of 90 degree wraparound on three-dimensional objects.
• Offers better edge definition and higher resolution than most other
printing systems therefore offering a method of decorating high quality
high priced items.
• Is a relatively inexpensive printing system particularly for multi-colour
and process colour printing which means reduced capital outlay.

51
 ADVANTAGES AND DISADVANTAGES

6.1 THE MANY ADVANTAGES OF PAD PRINTING:

52
 • Variety of substrates - Almost any material including glass, ceramic,
metal can be printed with suitable inks.
• Ability to print fine details - Resolution is far better than that of screen
printing in fact up to 120 lines / Cm (300 lines per inch)
• High resistance of printing inks - Depending on ink type used extremely
high resistance against mechanical abrasion or chemicals can be
achieved.
• Easy handling and little maintenance - Compared to other printing
processes pad printing is easy to learn
• Multi-colour printing: wet on wet - Possibility to apply multiple prints
without intermediate drying
• Short tooling-up times - Plates and inks can be exchanged within a few
minutes
• Low set up cost - Plates can be produced in-house
• Relatively low space requirement - Compared to other printing machines
pad printing equipment is space efficient
• Low drying cost - In the most simple case air drying at room temperature
is sufficient.
• Integration into complex systems, inline production and assembly lines -
For years now there has been a successful combination of pad printing
systems with injection moulding equipment or assembly lines.

6.2 LIMITATIONS OF PAD PRINTING:

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• Size of motive - Motive sizes are limited by plate, pad and efficiency of
the pad printing machine. The diameters of the largest efficiently printed
motives are currently approx. 30 cm.
• Layer thickness of ink film - The pad process uses plates up to a depth of
approx. 20-25µm (at the most 35µm). Thus conventional inks will result
in printed ink films of approx. 7µm. This layer thickness can be increased
correspondingly by multi-layer printing. Rough particles (e.g. glitter
pigments) are difficult to print in an efficient manner
• Printing speed - Even substrates can be printed a lot faster with other
printing processes.

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 APPLICATIONS

APPLICATIONS:

 Common applications of normal pad printing:

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 • Medical devices (surgical instruments, etc)
• Implantable & in body medical items (catheter tubes, contact lenses,
etc.)
• Golf ball logos/graphics
• Decorative designs/graphics appearing on Hot Wheels or matchbox
toy cars
• Automotive parts (turn signal indicators, panel controls, etc.)
• Letters on computer keyboards and calculator keys
• Identification labels and serial numbers for many applications
 Pad Printing is finding increasing favour in a host of commercial and
industrial applications
• Baseballs,bottles, light bulbs, clips, handles and knobs.
• Industrial parts and industrial pumps
• Containers, appliances, control buttons and automotive parts.
• Injection molded parts
• Furniture accessories
• Toys and hobby parts
• Promotional products
• Name plates
 Special applications of our project:
• Printing on capsule boxes for pharmaceuticals.
• Printing on paper cups and paper plates.
• Printing on paper egg holders.
• Printing on paper cones for textile industries.

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COST ESTIMATION

COST ESTIMATION

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 Components Price (Rs)
Base plate 700
( Mild Steel, 12mm thick)
C-Frame 3000
(Mild Steel)
Top plate 650
( bearing sleeve, mild steel, machined)
Pad Holding plate 535
( Mild steel)
Guide rod 300
( 2 No’s , Polish rod)
Pneumatic cylinder
1. (50x50) 1000
2. (50x300) 1500
Vice 2200
(stroke=300mm)
Ink cup 950
Screw rod 350
Surface plate 1500
(200x300, 10 mm thick)
Etch plate 1250
(100x600mm)
Pad 3200
(115x 65mm)
Direction Control Valve 1500
Fasteners 500
TOTAL 19135/-

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 CONCLUSION

CONCLUSION:

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 Eventhough pad pritning is already existing for the
solid substrates like plastics and metal,but it had a limitation of not using it for
the paper products. Now with our project it s possible to obtain prints on paper
products with minimum working pressure and compact design.

The machine can lead to minimize lots of error in the printing industries letting
an error free printing on the finished paper products also. The printing can be
easily done after the manufacture of the products irrespective of its shape, size
and material.

Hence leading to the great success , this pad printing machine can develop
impressions of any type on any typical components including the finished
paper products.

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REFERENCES

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REFERENCES:

BOOKS:
1. Pad Printing Technical Guidebook: John P. Kaverman
2. The stamp-pad printing book: Florence Harvey Pettit – 1979
3. The Complete Book on Printing Technology: Niir Board

PATENTS:
1. BS Adner, DP Bouchard - US Patent 5,806,419, 1998 - Google Patents
2. DWM Ho - US Patent 5,237,922, 1993 - Google Patents
3. PAD PRINTING MACHINE : Claus Morlock Wilfried Beron

WEB:
1. http://www.sodaltech.com/
2. http://en.wikipedia.org/wiki/Pad_printing
3. http://www.kinnariprintingmachines.com/
4. http://www.padprinters.com/
5. http://www.padprinting.in/
6. http://www.padprintingplatesonline.com/
7. http://www.inkcups.com/
8. http://www.freebase.com/view/en/pad_printing
9. http://www.halfbakery.com/
10.http://www.howstuffworks.com/
11.http://www.ritapad.com/
12.http://www.packmark.com.au/Pad%20Printing/

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