SAKATA INX . . .

Visual Communication Technology

CONCEPT OF INK KITCHEN IN CONVERTING INDUSTRIES

Presenter: R. S. Prasad.
Sakata Inx (India) Ltd
•Venue: PackAge Conference, Hall No.-8, Pragati Maidan, New Delhi
•Date /Time: 2nd December 2010 14:25 hrs to 14:50 hrs
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Sakata Inx India Limited – Introduction

ØSakata Inx Corporation Japan (SIC) founded in Year 1896. Ranks 4th in the
turnover ranking with 1.2 b US $ revenue

ØHas manufacturing bases in 16 countries with over 80 manufacturing sites

including USA, Europe, Japan, China, Malaysia, Vietnam, Indonesia, Thailand,
Philippines‘ & India

ØProduct range includes Solvent Based & Water Based Flexographic & Gravure
Inks, News Ink, Offset Inks, UV Inks, Water Based & UV Varnishes, Metal
Decorating Inks & Digital Inks & Toners.

ØSakata Inx has R D centre’s in Japan, USA and India to work on new
technologies, raw materials and provide products required by the customers and
also to meet the changing needs
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Sakata Inx India Limited – Introduction

ØSakata India is 100% subsidiary of Sakata Inx Corp. Japan & established in
Nov 1998
ØSakata India has two manufacturing facilities, Plant 1 at Bhiwadi & plant 2 at
Panoli ( Gujarat)
ØSakata India produce Gravure, Flexo and offset inks and is leading supplier to
all key convertors with excellent performance on Low to high speed machines

Ø Sakata India is ISO 9001: 2000, ISO 14001: 2004 & OHSAS 18001:1999
certified company (Certified by TUV Management Service GmBH

ØKnown in Indian Market as a supplier of high performance, high productivity &

consistent Inks, with high level of technical servicing & innovative approach to
work closely with customers.

ØHas been growing at a CAGR of 26% for the last three years, Current year we
expect to repeat this performance.
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Printing
• Printing is a process of reproducing text and 
image, typically with ink on substrate using a 
printing press.
• Ink is the carrier of the graphics and visuals 
intended to be printed on a substrate. 
• Both combined together is                        
VISUAL COMMUNICATION TECHNOLOGY
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Flexible Packaging: Flexo Printing

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Flexo Printing systems

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Flexible Packaging: Gravure Printing

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Gravure/Intaglio printing
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Ink Kitchen

• On the basis of Ink application and the needs to

manage inks, Sakata has been able to set the Ink
Kitchen Systems for Gravure Printing at various
locations.

• The Operational Excellence is well proven since over a

decade now.

• And the demand to manage Ink Kitchen is growing…

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Ink Kitchen: Objectives

1. To understand ink and its application correctly

and enhance operational efficiencies by minimising
losses.

2. To utilise base colour concept (about 15 colours)

to avoid high inventory of Fresh Inks in terms of all
special colour shades of a job.
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Ink Kitchen: Objectives

3. To provide consistent Press Ready Inks to the

press to eliminate the struggle to get the desired
colour shade on the press.

4. To maintain low inventory of Press Return inks

below assigned limit by ensuring its reuse in different
jobs.

5. To provide technical expertise in all aspects of

converting operations including cylinder proofing,
printing and post printing processes.
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Understanding Ink and its Application

Colourants / Pigments 5 – 30 %
Binder systems 15 – 60 %
Solvents 20 – 70 %
Additives 1 – 10 %
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Understanding Ink and its Application

Color Strength Hiding PowerLight Fastness Adhesive

(MT / UT) compatibility

Resistance
Flow Storage
Gloss properties
stability

Tinctorial
strength Abrasion Blocking
Shade
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Understanding Ink and its Application

Rub

Lightfastness
Resistance
properties Soap/Alkali
oil
Deep freeze

Heat
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Understanding Ink and its Application

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Utilising Base Colour Concept

3% 7% 13% 25% 50% 75% 100%

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Utilising Base Colour Concept

w
k

Yello
Blac

Red

Brown
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Consistent Press Ready Ink

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Control of Dilute Inks by Proper colour utilisation

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Control of Dilute Inks by Proper colour utilisation

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Technical Expertise: Understanding Colour

Inks Substrates
ƒ Pigments or Dyes
ƒ Type of Substrate
ƒ Solvents
ƒ Surface Energy
ƒ Resin
ƒ Compatibility with ink
ƒ Process Parameters
ƒ Resistance Properties
ƒ Analytical methods
ƒ Storage Condition
ƒ Instrumentation
ƒ Dimensional Stability
Calibration

Laminates
ƒ Ink / Adhesive compatibility
ƒ Adhesive / Sealant compatibility
ƒ Curing Condition
ƒ Bond Strength
ƒ Thermal Stability
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Technical Expertise: Understanding Colour

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Technical Expertise: Measurement of Colour

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Technical Expertise: Understanding Gravure Cylinder

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Technical Expertise: Understanding laminate

Substrate
Ink
Adhesive
Sealant
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Testing Inks For Various applications

Various tests can be listed as:
For Reverse application – Lamination grade:
1. Ink adhesion / Blocking
2. Ink GSM
3. Solvent retention
4. Odour
5. Required Lightfastness
6. AR/SR
7. Boil and Retort grade of Inks
8. Compatibility with various adhesive
9. Adequate Bond Strength
10. Compliance to food grade application
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Testing Inks For Various applications

For Surface application – Non Lamination grade:
1. Ink adhesion / Blocking
2. Ink GSM
3. Solvent retention
4. Odour
5. Required Lightfastness
6. Product Resistance: Water, Milk, Ghee, Oil Detergent
7. Heat Resistance
8. Rub / Scuff Resistance
9. Deep freeze Resistance
10. Compliance to food grade applications etc.
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Various Testing

Rub Resistance Tester Fade-O-Meter

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Various Testing

Bond Strength Heat Gradient Tester

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Ensuring compliance on Printing Inks

Conformation to international standard: With
world market merging together conformation to
different international standards (CONEG, FDA,
NL regulations of Japan, European Standard
EN71/3) has become almost the basic
requirement. These are basically to eliminate
hazardous substance such as Cadmium and its
Compounds, Cyanide Compounds, Organic
phosphorous compounds, Lead and its
compounds, Hexavalent Chromium Compounds,
Arsenic and its compounds, Mercury and its
compounds, PCB, Trichloroethylene and
tetrachloroethylene.
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Ink Kitchen

• On the basis of the operational excellence

through Ink Management Systems Sakata
has been able to consistently achieve
deliverables that is directly resulting into
benefits of the converters.

• These benefits can be outlined as:

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Ink Kitchen: No wastage

• No wastage for shade matching on the

machine due to variance in Ink colour
shade.
• The first registered print is well within the
approved LSD.
• Of course, we ensure no wastage of Ink
due to wrong mixing.
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Ink Kitchen: Minimum Shade matching

Time
• To establish Stranger jobs, we provide our
expertise of shade matching skill and
assist in approval of the color shade.
• For Repeater jobs we ensure dE below 2
so that no correction is required on the
machine.
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Ink Kitchen: Consistency of colour shade

• We provide total required quantity of ink

in the press ready form so there is no
deviation of colour shade throughout the
print run if all other parameters are
maintained.
• On the press we need to maintain the
viscosity through out the print run to
ensure the consistent print run.
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Ink Kitchen: Minimum Dilute Ink Stock

• We utilise the press return inks of one job

effectively by converting it for another job
and thereby ensure minimum dilute ink
stock.
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Ink Kitchen: Prompt Services

• Press Ready inks are supplied to printing

press within two hrs of the Ink
requirement ensuring no machine waiting
for inks.
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Ink Kitchen: Prompt Services

• We at Ink Kitchen manages colour by

managing Inks…
• And Ink Management results not only in
colour management but also adds to the
productivity and reduction of various
wastages…
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Emerging Technologies
• Sakata India has got the high performance ink
systems and within a span of 12 years has been able
to place itself as the main supplier of liquid printing
ink.

• Sakata India enjoys the market share more than

35% in total and more than 80% in the quality
segment.

• Sakata India has been able to strengthen itself in its

assigned territory of SAARC Nations, Middle East,
Africa and now strengthening itself in the erstwhile
USSR region.

• Sakata India extends various analytical solutions to

strengthen the flexible packaging market.
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Emerging Technologies

• As a latest product Sakata India has

launched the technology of High
performance Polyurethane Base Toluene and
MEK Free Ink System known as

BELLECOLOR
•
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THANKS!!!