PRINTING

PACKED DRINK

NAME MATRIX NUMBER

MOHAMAD LUKMAN BIN ZAINI 08DMP18F1053
MUHAMAD AZRI NAZMI BIN ABDUL 08DMP18F1062
BASID
VELLMA ERNICCA REVEUS 08DMP18F1087
YEOH JING YI 08DMP18F1067

LECTURER NAME:
PUAN GIHA BINTI TARDAN

JABATAN KEJURUTERAAN MEKANIKAL

DEC 2019
 TABLE OF CONTENT

CONTENT PAGES
Definition of water boc 3-6
Printing method and type of printer use 7-8
for the printing process

Flexography 8-23

Gravure 24-27
Conclusion 28
DEFINITION OF WATER BOX

Water box ( air kotak )it is multi-layer material that combines several films or foil into
single layer .There is a few layer material that used to produce this product:-

Paper
Paper is a fibre-based material produced from wood, rags or organic material. The types
of paper used in the packaging and graphic arts industries typically use wood and/or
recycled paper and board, which is then chemically or mechanically processed to
produce cellulose pulp. This pulp is bleached and processed in a paper making machine
to produce reels of paper which may optionally be coated or finished to provide a better
surface and/or improved visual appearance.

Paper may be between 0.07 mm and 0.18mm thick, with paper for printing and
packaging applications generally being in a range between 60 and 120 gsm. The
crossover point between paper and board is normally considered to be around 160 grams
per square meter (gsm), as it is only at this level that a fibrous material is likely to be
stiff and rigid enough to make a container.

Paper has a wide range of industrial applications including use for the packaging of
products as diverse as confectionery and cigarettes, as a component in packaging
laminates, and for many commercial print uses.
Carton board
Carton board (also called cardboard, paperboard or solid board) is the name for a range
of paper based materials that includes folding box board (FBB, GC or UC), solid
bleached board (SBB, SBS, or GZ), solid unbleached board (SUB or SUS), white lined
chipboards (WLC, GD, GT, or UD), some unlined chipboards, and certain laminated
boards.

To manufacture carton board, fibrous material, either from trees, recycled paper, or a
mixture of the two, is turned into pulp. It is then bleached and processed in a board
making machine to create a board consisting of one or more layers, which may
optionally be coated to provide a better surface and/or improved visual appearance.

The crossover point between paper and board is normally considered to be around 160
grams per square meter (gsm), as it is only at this level that a fibrous material is likely to
be stiff and rigid enough to make a container.

Cartonboard is primarily used in the packaging industry to produce all types of folding
cartons, but may also be used for graphics applications. For folding cartons the board
used will normally be in the range 200 to 600gsm, or 350 to 800 microns.
Film
A film is usually characterized as a thin synthetic resin layer. There are many types of
films and their use depends on their physical and chemical properties, which make them
especially suitable for a given application.

The most commonly used plastic films are low density polyethylene (LDPE),
Polypropylene (PP), bioriented polypropylene (BOPP), and polyester (PET).Printed film
is used for packaging, display materials, stickers, seals, and a wide range of other
graphic applications.

Films are generally characterized by their basis weight, expressed in g/m²; and
thickness, expressed in microns. For some films it is also useful to know their density,
expressed in g/cm3.The increasing awareness of environmental issues is intensifying
research into film substrates derived from renewable sources that are compostable.

Aluminium foil
Aluminum is produced from bauxite, an ore abundant in nature. From the rolling mill,
aluminum foils emerge with a natural shiny finish, almost as bright as a mirror, but also
can be produced with an as-rolled, satin-like finish called matte.

Aluminum foil has all of the unique functional characteristics of the aluminum alloy
from which it is made.

Because of its exceptional barrier properties, aluminum foil is used across a wide range
of flexible and other packaging applications to protect foods, drugs, cosmetics, and a
lengthy list of other items, most often in combination with other packaging materials.
Laminates
A laminate is a material that can be constructed by bringing two or more layers of
material together. This can include different material combinations from a wide
spectrum of flexible substrates including thin aluminum foil, film, and paper. These
materials have different physical properties and varying thicknesses that combine to
provide the required barrier performance.

Converted single- or multi-layer webs are used in a number of industries, from the
packaging of food and non food products to industrial applications including the
photovoltaic industry.
TYPES OF PACKED DRINK

TYPES BRAND
Printing method and type of printer use for the printing process

FLEXOGRAPHY

Flexographic Printing
Flexography (often abbreviated to flexo) is a form of printing process which utilizes a
flexible relief plate. It is essentially a modern version of letterpress which can be used
for printing on almost any type of substrate, including plastic, metallic films,
cellophane and paper. It is widely used for printing on the non-porous substrates
required for various types of food packaging (it is also well suited for printing large
areas of solid colour).

Applications:

Flexography is the major process used to print packaging materials

 Flexography is used to print;
 Corrugated containers,
 Folding cartons,
 Multiwall sacks,
 Paper sacks,
 Plastic bags,
 Milk and beverage cartons,
 Disposable cups and containers,
 Labels,
 Adhesive tapes,
 Envelopes,
 Newspapers,
 And wrappers (candy and food)
 The major unit operations in a flexographic printing operation are :

Image preparation
Image preparation begins either with camera-ready (mechanical) art/copy or
electronically produced art supplied by the customer.Images are captured for printing
by camera, scanner or computer. Then 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 colour is involved, a
colour proof is submitted to the customer for approval.

Plate Making

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;-

i. photomechanical,
ii. photochemical
iii. laser engraved plate

The photomechanical plate making method begins with making an engraving. This is
accomplished by exposing a metal plate through a negative and processing the
exposed plate in an acid bath. The metal engraved plate is used to make a master
which is molded out of bakelite board. The engraving is placed in a mold press. The
mold is produced by applying heat & pressure to the mold material (bakelite board),
which can be either plastic or glass, against the engraving under controlled
temperature and pressure. The bakelite board fills the engraving on the metal plate.
When its cooled you end up with a master mold for the plastic or rubber compound
that will be pressed into the mold under pressure and elevated temperature to produce
the flexible printing plate with raised areas that will transfer the ink.The second
method of flexo plate making is relief plates. This utilizes a solid or liquid
photopolymer. The sheet of photopolymer is exposed to light through a negative. The
unexposed areas are then washed away with solvent or water wash. This is fast
becoming the most common method of making plates.

The process differs depending on whether solid sheets of photopolymer or liquid

photopolymer are used, though the two processes are similar in general outline. In
both processes the plates are made in ultraviolet exposure units. A negative of the job
is placed between the photopolymer and the ultraviolet light source. The
photopolymer sheet or liquid is then exposed to ultraviolet light, hardening the image
area. Lastly, the plate is processed to remove the unhardened non-image area.
Photopolymer plates are replacing rubber plates because they offer superior quality
and performance at a lower cost.

Flexographic printing plates may be made by laser engraving, which is called direct
digital platemaking. In this process an image is scanned or computer generated. Then
a computer-guided laser etches the image onto the printing plate.
Process Overview

In the typical flexo printing sequence, the substrate is fed into the press from a roll.
The image is printed as substrate is pulled through a series of stations, or print units.
Each print unit is printing a single color.The process of printing each color on a flexo
press consists of a series of four rollers:-

I. Ink Roller
II. Meter/Anilox Roller
III. Plate Cylinder
IV. Impression Cylinder

The first roller transfers the ink from an ink pan to the meter roller or Anilox Roll,
which is the second roller. The Anilox roller meters the ink to a uniform thickness
onto the plate cylinder. The substrate then moves between the plate cylinder and the
impression cylinder, which is the fourth roller.

The impression cylinder applies pressure to the plate cylinder, there by transferring
the image onto the substrate. The web, which by now has been printed, is fed into the
overhead dryer so the ink is dry before it goes to the next print unit.

After the substrate has been printed with all colors the web MAY be fed through an
additional overhead tunnel dryer to remove most of the residual solvents or water. The
finished product is then rewound onto a roll or is fed through the cutter

Flexographic inks
Inks used for flexographic printing are highly liquid and normally dry by evaporation
as the substrates used in this printing process are non-porous and hence non-
absorbent. Since this is a high speed process the thickness of ink film applied is lower
than other printing processes. Water based inks, solvent based inks, electron beam
curing inks, ultraviolet ray curing inks chemically curing inks are the five major
varieties of inks used by this process.

Types:-
 Water Based
 Solvent Based
 V. Curable
 Chemical ink
 Electron beam ink

Water based flexo inks dry through evaporation and absorption on paper. This
evaporation requires a greater amount of fuel or energy to dry the ink. Coated papers
may be used to control the absorption through the paper. Due to the speed of the
presses and volume of inks consumed daily a pollution control system may be
necessary, especially if the printer is using solvent based inks.

UV flexo inks are commonly used for top coats and lacquers and are responsible for
many improvements in image quality of flexographic printing. The use of UV curable
coloured inks is rising within the flexographic printing industry, but product concerns
and equipment investment are obstacles. Note, water based or UV curable inks may
not be an option for some printers due to the substrate being printed or design of the
product.

Flexography printer
Stack type flexo printer

This machine is suitable for printing such packing materials as

polyethylene ,polyethylene plastic bag glass paper and roll paper etc. And it is a kind
of ideal printing equipment for producing paper packing bag for food, supermarket
handbag, vest bag and clothes bag, etc :

Features:
 Easy operation ,flexible starting accurate color register
 The meter counter can set printing quantity according to the requirement .Stop
the machine automatically at the set quantity or when the material is cut off.
 Lift and lower the printing plate cylinder manually ,It will automatically stir
the printing ink after lifting
 The printing ink is spread by the knurled cylinder with even ink color
 Reliable drying system coordinated with high-speed rotation ,it will
automatically break circuit when the machine stops.
 360 continuous and adjustable longitudinal register device
 The imported frequency control of motor speed adapts to different printing
speeds.
 There are inching/Stopping buttons on the plate roller base and material
rolling rack so as to make it easy operate the machine when the plate is
installed.
Roll of paper are fed through machine for printing process
Image go through roller to applied a few of colour

Printed image on substrate rolled into huge roller

Central impression flexo presses

Cutting edge technology and high manufacturing standards ensure premium print quality and
long-lasting value. With their varied repeat lengths and medium to super-wide printing widths.
CI flexo presses meet the requirements of the most demanding package printing applications.

Hy-Flexo CI
Huge paper roll fed through machine for printing process

Fountain ink where ink is supplied to roller to transfer to substrate

Ink is transfer to substrate ad substrate rolled into huge paper roller
Inline flexo presses

UV flexo and multi-process printing units, digital automation, tension and temperature control
offer exclusive solutions and best value for quality and innovation.

Master M6 line

Exceptional performance and flexibility

The MASTER M6 is designed for the foremost flexibility to print labels, flexible materials
and folding carton. It provides the highest health and safety guarantee for food packaging
applications.

All run lengths, all applications, all industries

 The press handles all types of substrates used for the production of labels, flexible
packaging or folding carton
 Multi-process, product enhancing and inline finishing applications
 Outstanding print quality and color consistency and repeatability.

Certified food safety

Exclusive total traceablity system for food packaging applications with UV TrackTM. The
UV ink curing of the printed substrate is monitored while the press is running with
certification of the whole printing process. This opens new opportunities for UV printed food
packaging production with new food safety certifications.

Safety Food safety and brand protection are major requirements. Anti-counterfeiting and
traceability are required across the entire supply chain. Customization, versioning,
personalization Packaging needs to reach all segments of society taking almost any shape and
size across multiple job lengths across the globe. Color control and brand image Color
consistency and control across all substrates needs to be guaranteed for brands to look good
across the globe. Sustainability Packaging production needs to reduce its environmental
carbon footprint – less waste across the entire supply chain. New and thinner substrates.
Recycling and re-use are the new rules. Faster time-to-market A growing number of products
need to reach consumers faster. Product lifetime is shorter. From product design to the
consumer experience, the supply chain has to be more agile

Exceptional flexibility

The MASTER M6 handles all types of substrates used for the production of labels, flexible
packaging or folding carton. – Reel-to-reel, reel-to-sheet, and reel-to-converting delivery –
Multi-process, product enhancing and inline finishing applications – Lamination technologies
- solventless, solvent-based, water-based – Cast & cure – Cold foil – Multiple printing
processes available - flexo, silk screen, gravure, inkjet

Food safety with UV Track

Exclusive total traceablity system for food packaging applications. The UV ink curing of the
printed substrate is monitored while the press is running with certification of the whole
printing process. This opens new opportunities for UV printed food packaging production
with new food safety certifications. Compared to solvent and water-based inks, UV inks
achieve higher print quality and color consistency combined with the absence of VOCs
(volatile organic compounds), improving ink stability and sustainability.

Digital Automation

The Digital Automation Project is a revolution in "thinking" and operating a labels and
packaging press.
It considers all the possible operations, makes them fully digitally checked, adjusted and
controlled

Technologies for self-adhesive label

An integrated mix of revolutionary technologies to enhance productivity in the industry of

self-adhesive labels, create new functional labels and "break" the "bottle-necks" of die-
cutting and waste stripping.

Technologies for flexible packaging

These technologies are available for printing on most difficult substrates. Most flexible
substrates can be converted, with excellent register and print quality.

 Accurate temperature control of chilled drums with less than 1°C temperature
accuracy on the substrate
  Accurate tension control with dancer/load cell operated unwinder, infeed, outfeed,
rewinder
 High quality manufacturing for perfect press alignment and web transportation
 Positive web transportation with driven chilled drums and short web path
 Multiple drying options for UV, water- and solvent based inks.

Technologies for carton & paper packaging

Heavy-duty manufacturing and multi-process technology allow for the production of added
value carton boxes and paper labels in short and long runs, all-in-one-pass. The perfect
solution for exclusive Carton and Paper Packaging.

 Heavy-duty manufacturing for all carton substrates (up to 550 gsm)

 Integration of all-in-one-pass printing processes (offset, flexo, gravure, digital,
embossing etc.)
 Digital Automation for short set-up times and limited wastes in multi-process
converting
 High-speed productivity (up to 200 m/min, 660 fpm)
 Flexibility to convert paper and carton.

Substrate goes to next print unit.red ink applied on cylinder.

Yellow colour applied to cylinder.

Printed substrate is fully applied with ink and it goes to dryer to complete drying so that
printed images on substrate no messy.
Huge roller paper form and ready to next process
2. GRAVURE

Gravure printing

The rotogravure process is a direct transfer method for printing onto wood-pulp fiber based,
synthetic, or laminated substrates, including,films such as polyester, OPP, nylon, and
PE,papers,carton board ,aluminum foil.The modern day rotogravure printing press uses a
printing cylinder which has been laser engraved with minute cells capable of retaining ink,
the size and pattern of which reflect the required image. These cells are forced to transfer
their ink directly onto the substrate by a combination of pressure and capillary action, so
producing the printed image. The process, also commonly called gravure printing, is used in
the manufacturing of food and non-food packaging, as well as labels, wall coverings, transfer
printing, and has a variety of further applications in the security printing, industrial, and
tobacco segments of industry.Rotogravure printing or just simply gravure printing is a type of
intaglio printing process which uses a rotary printing press.It involves engraving an image
onto a copper plated steel cylinder base.A rotogravure printing press has one printing unit for
each colour, typically CMYK or cyan, magenta, yellow and key (printing terminology for
black), but the number of units varies depending on what colours are required to produce the
final image.
Procees of gravure printing

Process of gravure printing

 The ink is applied directly to the cylinder and from the cylinder it is transferred to the
substrate.
 While the press is in operation, the engraved cylinder is partially immersed in the ink
fountain, filling the recessed cells.
 As the cylinder rotates, it draws ink out of the fountain with it. Acting as a squeegee, the
doctor blade scrapes the cylinder before it makes contact with the substrate, removing
excess ink from the non-printing (non-recessed) areas and leaving in the cells the right
amount of ink required: this tool is located quite close to the substrate so that the ink left
in the cells does not have enough time to dry.
 Next, the substrate gets sandwiched between the impression roller and the gravure
cylinder: this is where the ink gets transferred from the recessed cells to the substrate.
 The purpose of the impression roller is to apply force, pressing the substrate onto the
gravure cylinder, ensuring even and maximum coverage of the ink.
 The capillary action of the substrate and the pressure from impression rollers force the
ink out of the cell cavity and transfer it to the substrate.
 Then the substrate goes through a dryer because it must be completely dry before going
through the next colour unit and absorbing another coat of ink.
Components of Gravure Printing

Printing cylinder
A seamless tubular sleeve or full cylinder, made from either steel, aluminum, plastic, or
composite material, which is engraved with the image to be printed.

Doctor blade
The device that removes ink from the non-engraved portions of the printing cylinder and also
removes excess ink from the engraved sections.

Impression roller
A rubber covered sleeve that is mounted on a steel mandrel. Its primary purpose is to press
the substrate against the printing cylinder.
Inking system consisting of an ink pan, ink holding tank, and ink pump with supply and
return ink pipes.

Drying system
Consisting of a chamber which dries the ink once it is on the substrate and prior to it reaching
the next printing unit. Drier capacities are determined based on the required printing speed,
ink type (solvent or water based), and ink lay down volume.
Gravure printer
CONCLUSION

As a conclusion, there are two types of printing that make this paperboard more attractive
with a pattern and provide the best quality to market. The surface and structural design also
play a role in providing a stronger for producing products. Beside that, productivity
improvements at all levels of production and usage should play a role in every kind of
printing such as flexography and gravure. It aims to produce better quality products when it
comes to consumers. On top of that, packaging machinery and methods, including product
handling also need to be strengthened to produce a product. This is to prevent the product the
being manufactured from being damaged or not meeting the requirements of the factory. The
quality packanging also offers good results for sale when ready for processing through the
factory. In the end, some of these conclusions can have a very good impact on the product
being produced. Flexography and gravure printing is great for paperboard and other products
for sale to consumers out there.
REFERENCES

1. Soroka (2002) Fundamentals of Packaging Technology, Institute of Packaging

Professionals ISBN 1-930268-25-4
2. ^ Diana Twede (2005). "The Origins of Paper Based Packaging"(PDF). Conference on Historical
Analysis & Research in Marketing Proceedings. 12: 288–300 [289]. Archived from the
original (PDF) on July 16, 2011. Retrieved March 20, 2010.
3. ^ Brown, P.J. (1988), "Andrew Yarranton and the British tinplate industry", Historical
Metallurgy, 22 (1), pp. 42–48
4. ^ King, P.W. (1988), "Wolverley Lower Mill and the beginnings of the tinplate industry", Historical
Metallurgy, 22 (2), pp. 104–113
5. ^ King 1988, p. 109
6. ^ H.R. Schubert, History of the British iron and steel industry ... to 1775, 429.
7. ^ Minchinton, W.W. (1957), The British tinplate industry: a history, Clarendon Press, Oxford, p. 10
8. ^ Data extracted from D.P. Hussey et al., Gloucester Port Books Database (CD-ROM, University
of Wolverhampton 1995).
9. ^ Geoghegan, Tom (April 21, 2013). "BBC News - The story of how the tin can nearly wasn't".
Bbc.co.uk. Retrieved June 4, 2013.
10. ^ William H. Chaloner (1963). People and Industries. Routledge. p. 107. ISBN 978-0-7146-1284-3.
11. ^ Encyclopedia of Kitchen History. Taylor & Francis Group. September 27, 2004. ISBN 978-1-
57958-380-4.
12. ^ Diana Twede & Susan E.M. Selke (2005). Cartons, crates and corrugated board: handbook of
paper and wood packaging technology. DEStech Publications. pp. 41–42, 55–56. ISBN 978-1-
932078-42-8.
13. ^ Brody, A. L; Marsh, K. S (1997). Encyclopedia of Packaging Technology. ISBN 978-0-471-
06397-1.
14. ^ ASTM,2003, Standard Test Methods for Temperature Measurement and Profilling for Microwave
Suspectors, ASTM F874-98, American Society for Testing and Materials International, West
Conshohocken, Pennsylvania.
15. Tobacco Asia 2010, Allen Liao, Chinese Manufactures adopt multiple anti-countering strategies,
Q3 2010, visit http//www.tobaccoasia.net