Printing

1. No of equipments

Machine No of Colours No. of Made Maximum Cylinder Size

Name Machines Speed
(m/min)
Rotomec Old 8 1 Italy 250 1060
Corutti 8 1 Italy 350 1370
Rotoflex 10 1 Uflex 400 1370
Schiavi 10 1 Italy 300 1280
Rotomec New 8 3 Italy 400 1370
Rotoflex 8 1 Uflex 200 600
Comexi Flexo 8 1 Spain 400
Comexi Flexo 10 1 Spain 400

There are three types of printing:

Types Details Features Merits & Demerits

Surface This printing can be done on Ingrave Depth on Demerits
opaque and transparent cylinders 1. Cylinder cannot be used
screen from light to dark for other job.
2. Quality of grieve is not
that good.
Reverse This can be done only on Ingrave Depth on Demerits
transparent screen from dark cylinders 1. Cylinder cannot be used
to light for other job.
2. Quality of grieve is not
that good.
Flexo Plate printing is mounted on Imprint relief and is 1. Imprint can be changed
cylinder through both side made of rubber, as per the job
tape plastic, acrylic requirements.
2. Can be stored easily.

Process

When the thin film like Plain , BOPP, Matt, Substray Paper etc is being introduced to the Printing
machine through the unwinder it passes from the impression roller which imprints the engraved
through ink on the film. After that it passes from the heating chamber whose temperature is
approximately 60 C to 70 C, which is being adjusted according to the job. After this the rewinding is
done and is further sent for lamination/extrusion.
 Extrusion
No of Machine – 5 nos

Process:

Extrusion also known as poly coating. The process of Extrusion do not use adhesives instead uses
granule/ polymers.

The two films say WPP and printed sheet are released from either sides and from opposite direction
while the die in between melts the granules which on liquidation sticks both the films and is further
passed from the chilling drum for cooling. The sheet is then sent to slitting for further process.

Lamination
No. of Machines

1. Solvent less – 6 M/c

2. Base solvent – 5 m/c

Process

Solvent Less

There are 2 drums containing OH & NCO (Nitro Cellulose) in either drums which is further
transported to different exit pipes and the adhesive is pored between the film and printed film and
hence the lamination is done.

Solvent Base

There are two cylinders which releases two films and in between solvent with adhesive and hardness
is added to maintain viscosity which is added in the gel form between the films and lamination is
done
 Slitting
Make

1. KMPH – 9nos
2. Super slit – 2 nos

The slitting machine is basically for giving a cut to the laminated and printed films as per the
customer requirements a job card is issued according to production is led. The unwinder roll releases
the sheets and the direction is checked. Photocells are installed which checks the slit width and
through the bottom cutter shaft slit is cut and the roles of required dimensions are obtained.

There is a machine which is known as doctring machines and are 10 in numbers whose work is to
inspect and iterate the rolls.

Next step to slitting is packing, rewinding or wastage

 Holography
Make

1. Giletz

Size & No of machines

a. Rofo 910 MM – 2 nos

b. Rofo 1020 MM – 1 nos

Speed - 100m/min

2. Chinese

Size & No. of Machines - 1200 mm & 35- 50 m/min

Speed – 35- 50 m/min

Process

Firstly Unwinding is done and the next step is checking the position of the input horizontally and
then vertically and in the stamping press, a honeycomb plate with die mounted on it at the the
temperature of 130 – 150 C heading towards the stamping foil which is being pressed by counter
plate
 Packaging and Dispatch
Types of Packaging

Modes of transportation and cases

 Recycling Plant
Make -

No. of m/c – 5 nos

Capacity – 500t / month

The recycling pant was introduce to recycle the internally generated waste which was further
extended towards external plastic waste collection and recycling.

For EPR, waste is separated and accumulated at source and then in the form of bales are transported
to the recycling plant which are further transferred to the machines which treats each plant
separately which are mainly PP, Mix PE, PP 1no. grade etc, as per the inputs

While for PCR, washing is done as it is a road waste collection which passing on to the recycling
machine are converted into granules and can be converted to seat only.

Process

The plastic waste as input is being feeded through the conveyor and through the cutter/ compactor
are broken down into pieces which is further heated in Extruder at the temperature of 250 – 280C in
which further curing is done with water and further dried