Operations Production and Management

KP KAMIL PACKAGES (PRIVATE) LIMITED

Submitted to: -

Sir Irfan Ali Group Members: (6G)

 Muhammad Yaqoob Akmal

 Muhammad Arsalan Saleem
 Adeela Majeed
 Marium Rana
 ABSTRACT

As our topic is on Layout Process and for this we visit Kamil Packages to make a report.
In December 2010 APH started a side business of Gravure printing and finally start
operating in the end of January 2011. This business started in the name of grandfather
Kamil and business named Kamil Packages (Pvt).Ltd. This business started on the
future market demand and started with the partnership among all brothers. KPS started
the business with the same vision, same working departments and layout process.

KP dealing with many companies but there majors clients are Kolson, Shan, Danpak,
Ashrafi foods and etc. KP not just treat them as a client but they are also give value to
them. KP makes relation for long term and corporate them in every stage.

The analysis of production process we found out that their production process is well
managed and organized as they have very skilled employees and labors also they have
their plant at ideal location in context of transportation cost saving as their plant is
located near to the port as well as closer to their major clients also it is very feasible for
the workers.

KP is having a good working environment and always gives importance to the employees
and facilities. In organization the value to the employees are very important and this what
KP always gives to their workers that we saw in the organization. The organization is
serving since 5 months but what we saw there between the workers in team working
cooperating between each other to achieve success.
 Table of Contents

Introduction 3

Clients of KPS 5

About Gravure Printing 6

How job Order get done 7

Production Process 8

PP (Raw Material) 9

PP (Printing Process) 10

PP (Lamination Process) 12

PP (Slitting Process) 13

Conclusion 14

Recommendation 14

References 14
 KAMIL PACKAGES (Private) Limited
Introduction

Akmal Print House (Private Limited) was created on March 19 1963. It is standing today
as the finest printing the packaging pharmaceutical materials company in Karachi.

As a leading pharmaceutical printing company we make a real difference in the global

health care by true color in life through printing and especially to the developing world.
We believe that this is both an ethical imperative and key to success. Companies that
respond sensitively and with commitment by changing their business practices to address
such challenges will be the leaders of the future. APH operates mainly in Designers,
Printers and Binders.

In December 2010 APH started a side business of Gravure printing and finally start
operating in the end of January 2011. This business started in the name of grandfather
Kamil and business named Kamil Packages (Pvt).Ltd. This business started on the
future market demand and started with the partnership among all brothers. KPS started
the business with the same vision, same working departments and layout process.

APH deals in value, some of our key brands include Augmentin, Panadol, Seretide,
Betnovate, Iodex, Ultimate Plus Lenses and many more other pharmaceutical companies.

Corporate Department

M. Akmal ----- Managing Department

S.M. Rafi ----- Manager

M. Afzal ------ Technical Director

Zafar Safi ------ Q.C Director

Mission Statement From M. Akmal --- Managing Director

KPS mission is to provide quality printing. We believe in value performance. We always

try to attain success and make our standard as compare to multinational company. We
always work with passion.
Duty of Manager

Duty of mine is to look for the products quality and to check the delivery time. My staff
trusts me and I trust my staff. I am controlling over 150 staffs daily and always have to
check them. The Delivery Challan is also issued by me. Without this challan the delivery
of good cannot be possible. I always have to look out the transport availability and
always deliver my goods on time in present and the future.

Spirit of KPS

 Performance with Integrity

Delivering on promises with organizational and individual trustworthiness.

 People with Passion

Inspiring, motivating, and enabling people to do their best work.

 Everyone Committed, Everyone Contributing

Enabling, encouraging, and allowing all employees the opportunity to make meaningful
contributions and succeed on merit.

 Develop Self and Others

Learning continuously and developing professional potential and ability. Leaders act as
teachers, coaches, and champions of development, creating career-long learning across
the organization.

Our Press Location

A/70 Mangopir Road,
S.I.T.E opp. Valika Hospital,
Karachi 75700. Pakistan
Telephone: 2595305-8
Fax: 2595309
 CLIENTS OF KPS
Some of our major clients are

 DANPAK

 SHAN FOODS

 ASHRAFI FOODS

 WONDER FOODS

 KOLSON

 TAPAL
Gravure Printing:
Printing processes used for catalogs, magazines, newspaper supplements, cartons, floor
and wall coverings, textiles, and plastics. The Bohemian Karel Klíc made photogravure a
practical commercial process in 1878. An image is etched in the copper surface of the
printing cylinder as pits or wells of different depths. In rotogravure printing, the cylinder
rotates through a trough filled with fast-drying ink. A thin steel doctor blade removes the
ink from the surface but not from the wells. The cylinder comes in contact with the paper,
which draws the ink out of the wells. Because of the various depths of the wells, a full
range of tonal values can be printed; in reproducing illustrations, gravure comes closest to
simulating continuous-tone copy. In colour printing, a separate cylinder is prepared for
each colour.

Advantages:
Gravure is the quality printing process producing fantastic and constant reproductions
throughout the print run because the secret of the gravure process lies in the cylinder.
More robotics and total plant computer control systems will bring many further
advantages for gravure. It is very simple printing process and can produce millions of
perfect bags at enormous speed.
Another useful advantage of gravure is that it produces superb colors and gloss on
relatively low quality film, which can bring big cost saving.
 HOW JOB ORDER GET DONE

Firstly, customer orders the amount of material they want then via E-mail, telephone or
through other medium. Then the production department checks their capacity and
available resources and their production schedule (time of fulfillment of order) after it
company communicate with the supplier for the acquisition of raw material and after the
receiving of raw material process get starts and production department try to complete the
job as soon as they can. After the completion of the order it supply to the respective
customers through trucks or other medium of transport.

PRODUCTION PROCESS

The steps required in our process include raw material receiving, raw material quality
control test, printing, printing material quality control test, lamination, quality control,
slitting and finally quality assurance test. The details of these steps are given below.

PRODUCTION PROCESS

Raw Material
We use the combination of BOPP and MCPP solvent. The details of these materials are
given below.

Biaxially Oriented Polypropylene (BOPP) films are used in

an almost limitless array of flexible packaging applications,
pressure sensitive tapes, labels, stationery, metallizing,
consumer products and a wide variety of non-packaging
uses.

BOPP Products has an extensive product line available in a

wide range of film gauges and desired performance
properties. BOPP films are manufactured by proprietary
coextrusion and biaxial orientation processes, which produces films with excellent gauge
control, consistency and roll profile.

"Biaxially Oriented" means that the polypropylene film is stretched in both the machine
direction (MD) and across machine direction (AMD). Because of its superior strength at
low gauges, flatness, clarity and excellent printability

CPP film & MCPP are widely used as printing, sealing material for flower and food
arrangements, detergents and packing dry foods such as tea, crackers, biscuits, dressing,
etc.

CPP film adopts a special processing of 3-layer co-extrusion, and is a heat-sealing

material used for variety of packaging purposes. It can be laminated with BOPP and
BOPET or directly packaged after printing.

CPP film has high transparence and gloss, low COF, low sealing temperature, high
sealing strength.

It took 2 months in receiving the raw material from the supplier as this time include
shipping process and the process at the port.

Raw material imported from China, Dubai and Egypt.

Printing Process (YONG FONG MACHINERY-China)

1000 kg of raw material took 15 hours in printing process.

Cost of printing per kg is Rs.400 is means the printing cost of 1000kg will be 4lac.

The major unit operations in a printing operation are:

 Image preparation
 Plate making
 Printing
 Finishing

 Image Preparation

Image preparation begins with camera-ready (mechanical) art/copy or

electronically produced art supplied by the customer. Images are captured for
printing by camera, scanner or computer. Components of the image are manually
assembled and positioned in a printing flat when a camera is used. This process is
called stripping. When art/copy is scanned or digitally captured the image is
assembled by the computer with special software. A simple proof (brown print) is
prepared to check for position and accuracy. When color is involved, a color
proof is submitted to the customer for approval.
  Plate Making

Flexographic and letterpress plates are made using the same basic technologies
utilizing a relief type plate. Both technologies employ plates with raised images
(relief) and only the raised images come in contact with the substrate during
printing. Flexographic plates are made of a flexible material, such as plastic,
rubber or UV sensitive polymer (photopolymer), so that it can be attached to a
roller or cylinder for ink application. There are three primary methods of making
flexographic plates; photomechanical, photochemical and laser engraved plates.

 Printing Presses

The five types of printing presses used for flexographic printing are the stack
type, central impression cylinder (CIC), in-line, newspaper unit, and dedicated 4-,
5-, or 6-color unit commercial publication flexographic presses. All five types
employ a plate cylinder, a metering cylinder known as the anilox roll that applies
ink to the plate, and an ink pan. Some presses use a third roller as a fountain roller
and, in some cases, a doctor blade for improved ink distribution. 

 Inks

Flexographic inks are very similar to packaging gravure printing inks in that they
are fast drying and have a low viscosity. The inks are formulated to lie on the
surface of nonabsorbent substrates and solidify when solvents are removed.
Solvents are removed with heat, unless U.V. curable inks are used. 

Ink comes in drums which are weighted in kilos. 1000kg printing includes 440mg
approx ink. 1 kg cost Rs.80

After the process of printing the film roll transfer to the Lamination department.

Printing Material test:

After printing process the Curing test is done to test the printed job and eliminate the
defected material.

Lamination
The process of applying a film of plastic on the surface of any item is known as
laminating. When plastic coating is added to any item it becomes tear-proof and
waterproof, since the laminating film encapsulates the item completely by being bonded
to both its sides.
Lamination process took 18 hours for the material of 2000 kg as 1000 kg of printing
material sandwiched with 1000 kg of film of plastic. Plastic cost per kg is Rs.130
according to which 1000kg cost 1.3lac.

Laminating Machines: -

The laminating process is quite simple, although its development was not easy.
Laminating machines these days are products of decades of perfection and refinement,
which has resulted in producing two of the most common types of lamination processes:
the Pouch Laminating Machine and the Roll Laminating Machine.
The machine that we are using currently is Roll Laminating Machine.

Roll Laminating Machine: (Sino Tech Machinery -Taiwan)

This machine can be used to preserve and protect a wide variety of documents between
the sheets of laminating film. These machines are available in a wide range, from those
specially designed for schools to heavy-duty machines used in industrial settings or
commercial purposes. The commercial types of these laminating machines come in many
kinds of format sizes to meet the requirements of in-house graphic departments, business
service centers, print shops, copy shops, and so on. Roll laminating machines meant for
schools can provide a cost effective way of preserving teaching materials and even the
work of students. Designed for flexibility, quality, and convenience, roll laminating
machines have various features like adjustable control of heat, variable control of speed,
adjustable tension, and automatic shut down.
 Slitting Process
Several methods are available for soft materials like plastic films and paper. Razor
blades, straight, or circular blades are being used. Some blades cut through the material
while others crush the material against a hard roll. Those are similar to knives and cut the
material into narrow strips, which are called coils when being rewound. The cutting
blades can be set to a desired width. Some machines have many blades to increase the
options of cutting widths, others have just a single blade and can be set to a desired
location. The slit material is being rewound on paper or plastic cores on the exit side of
the machine.

The process is used because of its low cost and high

precision for mass production. Some machines have a
program that monitors the blades and sharpens the
blades often to maintain the quality and precision of
the cut.

Slitting process took 18 hours and after slitting total

material of 2000 kg become 1850 kg as 150 kg of
material cut from extreme sides of film.

To understand this process let’s take an example of 1850 kg of final product. 1000 kg raw
material go for the printing process and 1000 kg of material include in the process of
lamination then they combine together like a sandwich and final product that is made
after slitting have weight of 1850 kg as 150 kg of material waste in slitting process as
result of cutting the edges of film.

After Completion of Final Product:

Transfer to warehouse, which is having a Capacity of 2000 tons.

Total Area of Plant

Total area of plant consist of company is 1000sqft
Area of Machinery ground floor is 700sqft
Area of Machinery first floor is 800sqft
Warehouse consist of 550sqft

CONCLUSION

After the survey of the company and by the analysis of production process we found out
that their production process is well managed and organized as they have very skilled
employees and labors also they have their plant at ideal location in context of
transportation cost saving as their plant is located near to the port as well as closer to their
major clients also it is very feasible for the workers and other employees like the hospital
is there in case of emergency also the mosque is there and working condition is also good
for employees and worker. These factors increase the productivity of employees and
motivate them towards efficiency. They are very conscious about their quality of printed
material as this is the core value for their business and this unique characteristic
differentiates them from their competitors and that’s why they have clients those are
leader in their respective businesses and so the demand is increasing at very high rates
with the passage of time.

Recommendations
We noticed that this kind of process has lots of wastage like if a plastic roll is break down
between the process then it becomes very complicated to restart the process so they
should adopt some very sophisticated method while rolling of the plastic film so they can
avoid the wastage and can save the excess cost.

References:
Mr. Muhammad Hammad Zia (Plant Manager) 03212823548

http://encyclopedia2.thefreedictionary.com/
www.granwell.com/bopp/
www.imexbb.com/cpp-film-mcpp-film
www.pneac.org/printprocesses/gravure/
www.buzzle.com/.../laminating-process
www.dictionary30.com/meaning/Slitter