AN INDUSTRIAL TRAINING REPORT

Submitted by

xxxxxxxx

in partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

PRINTING AND PACKAGING TECHNOLOGY

DEPARTMENT OF PRINTING AND PACKAGING TECHNOLOGY

COLLEGE OF ENGINEERING GUINDY

ANNA UNIVERSITY, CHENNAI

JULY 2022

1
 ACKNOWLEDGEMENT

I would like to thank Dr. K. Senthil Vadivu, Head of the Department and Dr. M.
Kanchana, Assistant professor, Industrial Training Co-Ordinator for arranging in-
plant training. I would like to thank the management of BEST LABELS PVT .
LTD and THE TIMES OF INDIA PRESS for allowing us to undergo training
and to know about the various works in the Printing and Packaging industry
which helps us to easily relate the theory studied with the real industry platform. I
made the best use of this wonderful opportunity and it helped me to gain a lot of
experience.

Name:xxxxxxxxxx

2
Training schedule :

S.n No. Of
From To Company name
o days

1. 19.07.2022 01.18.2022 BEST LABELS 14

2. 03.07.2023 14.07.2023 TIMES OF

INDIA, 11
CHENNAI

3
 1. BEST LABELS PVT. LTD.,

1.1. COMPANY PROFILE

1.2. COMPANY LAYOUT

1.3. SUBSTRATE RANGE AND SPECIFICATION

1.3.1.RAW MATERIALS

1.3.1.1. FOR PRINT

1.3.1.2. FOR LAMINATE

1.3.1.3.VARNISHES

1.4. RANGE OF PRODUCTS

1.5. MACHINES AND THEIR SPECIFICATIONS

1.5.1. GALLUS EM 280

1.5.2. TARNG YUN PLATE MOUTER

1.5.3. PRATI SATURN TE400 SLITTER

1.5.4. ALCA GAMUT 250 (LABEL PRINTING - ROTARY)

1.5.5. BANG SUNG MACHINE

1.5.6. MARK ANDY 530

1.5.7. SUN FUTURA AVT – QUALITY CHECK UP

1.5.8. FUTURA CORE SLITTING MACHINE

1.5.9.VARIABLE DATA PRINTING-DOMINO K600I

1.6. PREPRESS

1.7.QUALITY CHECK UP

1.8. PARAMETERS CHECK

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1.9. JOB TICKET DETAILS

1.10. POST PRESS - DISPATCH

1.11. CONCLUSION

2. TIMES OF INDIA PRESS

2.1. INTRODUCTION

2.2 . COMPANY PROFILE

2.3. PRODUCT RANGE

2.4. SUBSTRATE RANGE
2.4.1. WIDTH BASIS
2.4.2.BRAND BASIS
2.4.3. NEWSPRINT BASIS
2.5. INFORMATION TECHNOLOGY
2.5.1.CTP NETWROKING
2.5.2.PRESS IT

2.5.3.GENERAL IT

2.5.4.ELECTRIAL IT

2.6. INFORMATION TECHNOLOGY

2.7. CONSOLE UNIT

2.8. MAKE-READY

2.9. PROCESS WORKFLOW

2.10. INNOVATION
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2.11. UTILITY

2.11.1. WATER

2.11.2. POWER

2.11.3. AIR-CONDITIONING

2.12. 5 S MANAGEMENT

2.13. PRESS MACHINE CONFIGURATION

2.14. PRINT PROBLEMS AND RECTIFICATION

2.15. WASTE ACCUMULATION AND DISPOSAL

2.16. OUTCOME

3. SAFFIRE OFFSET PRINTER

3.1. COMPANY PROFILE
3.2. PRODUCT RANGE
3.3. SUBSTRATE RANGE
3.4. PRE-PRESS
3.4.1. PLATE MAKING PROCESS
3.5. PRESS
3.5.1. MACHINES AND THEIR SPECIFICATION
3.5.1.1. SCREEN PLATERITE 8600NII-ZSE (CTP-EXPOSURE)
3.5.1.2. HY-PS-900 (CTP-DEVELOPER)
3.5.1.3. BASYSPRINT UV- SETTER SERIES 800 (CTCP-EXPOSURE)
3.5. POST-PRESS
3.5. OUTCOME

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 1.1. COMPANY PROFILE
The best labels is a label printing company, engaging in business activities, a
seamless process for small and medium enterprises as well as large level business.
The business came into existence in 2001, and gained a name in this field. The best
labels company located at No. 38, 5th Street, Thirukumarapuram, Arumbakkam,
Chennai, Tamil Nadu 600106. India's leading B2B marketplace, offers a wide
range of products and the product list includes garment tag, labels, custom printed
labels, food labels, T shirt labels, automative labels.
Bestlabels provides quality labels and products in affordable prices with their
experienced employees team. Their working environment in press and the
employees involvement in the work as a family has allowed them to become a
best choice for labels in Tamilnadu

1.2. COMPANY LAYOUT:

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 1. Wine & spirits

2. Health care& pharm

3. Transportation & logistics

4. Chemicals & lubricants

MACHINE
5. Personal care HALL 2
6. Foods & Beverages
MACHINE HALL 1
7. Automotive & electronics

8. Garment labels

9. Warning labels

DISPATCH

STAIR
PLANNING ROOM

1.3. SUBSTRATE RANGE & SPECIFICATION

1.3.1. RAW MATERIALS:
8
 1.3.1.1. For print
1. FassonFaspet
2. Fasson TT2C FASCI
3. FassonTranscoat
4. FassonFasprint
5. Fasson Synthetic
6. Fason Fascoat XTRANG NG
7. FassonFasfilm Clear
8. Fasson 1mcl Print
9. Fasson UDV
10. FassonFoamtag 90mm
11. Fasson Direct Thermal
12. Fasson PE 85 white
13. Fasson PE 85 Clear
14. Fasfilm plus white
15. Fasson 74U synthetic paper
16. Fasson 2ml white polyester
17. Fasson PP30 clear TC
18. Fasson PET MATT
19. Fasson 4MIL BATTER LAB EL VINYL
20. Fasson 60U white PP TC SW8563

1.3.1.2. For laminate :

9
 1. Matt void
2. 50 micron brushed silver TC
3. Anchor lamination
4. 1 m printable lamination 77955
5. Cold gold foil
6. Cold silver foil
7. Hot silver foil
1.3.1.3.Varnishes:
1. Matte varnish
2. Texture varnish
3. High resistance varnish
4. Gloss varnish
5. Over printable varnish (opv)
6. UV

1.4. Range of products:

1. Wine & spirits
2. Health care& pharm
3. Transportation & logistics
4. Chemicals & lubricants
5. Personal care
6. Foods & Beverages
7. Automotive & electronics
8. Garment labels

1.5. MACHINES AND THEIR SPECIFICATIONS:

1.5.1. GALLUS EM 280:
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 The Gallus EM 280 is the perfect tool for producing high-quality self-
adhesive labels affordably, medium-sized to tiny runs. It issimple to use, enables
flexiblea mix of printing methods has a platform that can alter quickly
fortransition periods, which together compriseit is suitable for anyone beginning
inUV and water-based
ANILOX ROLLER
LPI BCM CM
515 2.39 3.7
300 4.2 6.15
240 5.4 8.37
320 3.8 5.89
130 8.72 13.5
515 2.39 3.7
320 3.8 5.89
420 2.91 4.5
360 3.31 5.12
75 13.94 21.6
190 6.51 10.08
(WB) flexographic printing. Additional upgrades includehandling hot foil, rotary
screen printingboth cold foil printing and embossing.

Machine specifications
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Mechanical machine speed max. 150 m/min. 492

ft/min.

Web width max. 282 mm

Printing Printing width for flexographic printing max. 280 mm 11"

Format length for flexographic printing max. 457.2 mm 18"

Format length for flexographic printing min. 203.2 mm 8"

Printing width for rotary screen printing max. 270 mm 10 5/8"

Printing width for rotary screen printing min. 130 mm 5 7/64"

Format length for rotary screen printing max. 533.4 mm 21"

Format length for rotary screen printing min. 269.9 mm 10

5/8"

Printing width for hot foil embossing 280 mm 11"

with web width max. 282 m 11 6/64"

Format length for hot foil embossing max. 552 mm 21 3/4"

Format length for hot foil embossing min. 280 mm 11"

Format length increment 3.175 mm 1/8"

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Number of print operations max. 12 Drying UV

Hot-air drying

Flatbed processing Processing width max. 280 mm 11"

Format length max. 304.8 mm 12"

Format length min. 139.7 mm 5 1/2"

Format length increment 1.587 mm 1/16"

Rotary processing Processing width max. 280 mm 11"

Format length max. 457.2 mm 18"

Format length min. 203.2 mm 8"

Format length increment 3.175 mm 1/8"

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1.5.2. TARNG YUN plate mounter:

All sorts of narrow web presses are compatible with it. Two sets of high
magnification CCD cameras are required for precise vision registration. Cross
mark targets on flexo plates may be seen clearly on the screen thanks to a special
lens and lighting system. Custom builds can be made to the appropriate cylinder
size.

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PLATE MOUNTING:
Handle all components at room temperature.
Plate and cylinder cleaning with a mixture of 50% alcohol and 50% water
Use small air nozzles when wearing sleeves.
Tape the plate's perimeter with just a thin fringe.
The join of the tape shouldn't be placed just below the plate's join.
To make it simple to remove the plate from the cylinder after mounting, chalk
powder is placed to the rear side of the plate.
Line by line, wrap the tape around the plate cylinder. Squeegees are the finest
tool for this.
On a little portion of the tape, only attach the plate. Utilize liner material to
prevent plate and tape from coming into touch too soon.
To strengthen the binding, apply pressure to the plate using a rubber roller.
Avoid getting the solvent on the glue when cleaning the plate during the print
run.
The plate should be removed at a sharp angle, carefully and smoothly.
Finally, smoothly and at a sharp angle remove the tape.

15
 TECHNICAL SPECIFICATION:
Machine Dimensions (Length, Width, Height): 755mm X 630mm X 360mm
(30° X 14" X 25")
Net Weight: 80 kg ( 180Ibs)
Power Supply: 208-240V, single phase, 50/60Hz
or
100-120V, single phase,
Observation: CCD video cameras with 30X
optical magnification
Monitor: 8”register screens
Illumination: LED
Suitable for cylinder widths: 178 ~ 635 mm
Machine Dimension ( LxWxH ): 755 x 355 x 630mm ( 30”
x 14” x 25” )
Net Weight: 60 Kgs (180 lbs)
Power Supply: 100-240V, single phase, 50/60 Hz
or 110V, single phase, 50/60Hz

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1.5.3.PRATI SATURN TE400 SLITTER:

PRATI SATURN TE400 SLITTER is a full servo machine with a slitter &
rewinder. It has electronic and automatic control for unwinding tension constant
on the web servo die-cutting unit for front side model FT330-R3 with die-cutting
cylinder Z96 and in-setting unit for pre-printed labels. It has errors detection unit
and working programmes for MMLD. There are 4 IR photocell for MMLD with
error placement on the correcting table and 2 additional rewinder shaft 25mm and
40mm(76 mm included). The slitter contain self-sharpening shear slit unit
inclusive of 4 blade groups and optional razor slit unit. There is servo-driven web
tension and motion control and optional built-in reel loader.
Additional advantages include glue-free hooking technology, a small
design, and clean, core-lane-only rewinding.

17
 With a completely automatic slitting blade and label applicator control and
the ability to use a variety of attachments, size changeover only takes a few
minutes. From September 15 to September 18, Prati will be exhibiting its simple-
to-use, quick, and dependable Saturn te400 full servo slitter inspection rewinder at
Eurosia Packaging 2011 in Istanbul.
The Saturn TE400, sold by Imex Group in Turkey, is outfitted with the bst
Shark 400 4K inspection system, which offers 100% color print flaw detection.
This device will be on display at the bst booth, located in hall 4 at stand 402f.

Technical specification:
Max. working band width: 330 mm
Max. speed of label: 250 m/min
Fixer unwinder shaft: 76 mm
Max. unwinding diameter: 50 mm
Max. optional unwinding diameter: 1290 mm
Interchangeable pneumatic rewinder shaft: 76 mm
Max. rewinding diameter on 1st shaft: 600 mm
Max. rewinding diameter on 2nd shaft: 400 mm
Min. cutting/slitting width: 400mm
side trim minimum width: 1,5 mm
overal dimension: 220x114x145cm
Series of rewinder shafts from 24,9 to 152 mm

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1.5.4. ALCA GAMUT 250

Alca Gamut 250 is a 6 colour printing machine with free standing away
flat bed die cutting unit, hot foiling unit, lamination and computer sprocket
hole punching unit for performing online operation. The ALCA Gamut 250's
Modular Construction enables for the smooth and seamless incorporation of
future technology improvements. The several advantages of alca gamut 250
are Computerized Web Feed Control, Print any Repeat Length (Between 5 -
215 mm) by Just Programming, Same Set of Ink Rollers and Single Plate
Cylinder for all Printing Jobs, Less Inventory Costs, Print Heads placed on
Linear Motion Guides for precise movements, Auto Web Tension Control
Mechanism Ensures Precise Registration, Inter Station - UV Curing,
Impressively Short Set-up Time and Minimum Web Wastage, High Quality

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 printing on all Ranges of Label StockHigh Returns on short to Medium print
Runs.

ALCA GAMUT 250 (Label

Model
Printing - Rotary)
Maximum Web Width 260 mm
Maximum Print Width 250 mm
Repeat Length 5 -215 mm
Rotary Mode of Operation - Max. Print
251.3 x 250 mm
Area
Maximum Printing Speed 9000 IPH
Number of Letter Press Print Heads 4/5/6/7
Number of Flexo Print Head 1 (Optional)
Unwind Reel Diameter 800 mm (Maximum)
11 Rollers including 2 Larger
Inking unit
Diameter of Form Rollers
Power Source AC Three Phase Input, 380V
Flat Bed Die Cutting Unit
Maximum Die Cutting Area 210 x 240 mm
Maximum Cutting Rule Length 5000mm
Maximum Speed 12000 strokes Per Hour
Flat Bed Hot Foiling Unit
Maximum Foiling Area 210 x 240 mm
Foil Die Thickness (Maximum) 3mm
Slitter Rewinder
Rewind Shaft Diameter 2 shafts of 3" Dia.
500mm (Shaft 1) & 400mm (Shaft
Finished Roll Diameter
2)

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1.5.5.BANG SUNG MACHINE:

Features
High quality servo motor driven computer feeding system providing our
customers of quality printing and die-cutting.
Servo motor driven easier and accurate 2nd pass system.
Extensive functions of in-line unwinding + printing + hot-foil stamping +
die-cutting + laminating + either rewinding or sheeting per instruction.
Simple operation by simple manipulation of the touch screen and switches.
Guarantee high precision for a long period of time.
Increased durability with high strength material
Cast made main frame resulting in stable running.
Ideal for many type but small quantity of orders. (easy to change printing job)
Rotary die-cutting (tooling) is available per instruction.

Specifications
Electric power : 3phs 220v/380v 60/50hz per
instruction
Maximum printing & die cutting paper speed : 180rpm (10, 800
stroking/hour)
Maximum paper width : 310mm
Colors : off white

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Rotary printing section
Maximum printing area : 300 x 270mm
Maximum printing feeding : 270mm
Main motor : 5.5kw
UV curing : 4kw/unit

Die-cut section
double die-cutting stations
precise feeding system driven by high quality servo motor equipped
servo control precise scanning system for 2nd pass operation
synchronized running with rotary printing section
Maximum cutting dimensions : 300/310mm
Main motor : 2kw

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1.5.6. MARK ANDY 530:
The Mark Andy 830 is a modestly priced, central impression flexographic
web converting system, built to support converters entering the label market.
Operator friendly with convenient access to print stations and press controls.
1985 Mark Andy 830 7in used flexo press featuring 3 colors, 3 die stations, web
guide, 2 product rewinds, 1 waste rewind, 1/8 gear pitch.
Features
Drive System : 3hp DC solid state control
Gearing : 1/8 inch CP or 32 DP
Die Cutting : In-line rotary die cutting
Drying & Curing : IR drying
Die Cutting : Dual die station with underside capabilities
Waste Wind Up : Pneumatically controlled
Decoration : Laminator

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Technical specification:
Web Width : 10 inch (250mm)
Max Speed : 300 fpm (91 m/min)
Substrate Range : 2-10 mil (50-250 micron)
Max Die Cut Width : 10 inch (250mm)
Print Repeat Range : 5.5-15 inch (140-381mm)
Die Repeat (Top) : 4-15 inch (102-381 mm)
Die Repeat (Bottom) : 4-9.25 inch (102-235 mm)
Unwind Capacity : 18 inch (457mm)
Rewind Capacity : 18 inch (457 mm)

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1.5.7. SUN FUTURA AVT – Quality check up:

AVT machine is mainly used for quality check up in the printed substrates
which is labels and for slitting and numbering over the labels. The quality over
the printed labels is checked and the machine runs in a slow speed during the
numbering process for counting and accuracy. AVT slits the subtrates into 9
parts. The machines can also check for colour correction, text blurring, trapping
problem registration problem, text stroke mismatch and image correction and
alignment with reference to the pre-press design. The print head in the AVT
panel before the slitter is used for the numbering and batch number printing.
Specification:
Max speed : 200m/min
Min speed : 80-90 m/min
Max length : 280mm
Min length : 10mm
Total blade count : 8

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1.5.8. FUTURA CORE SLITTING MACHINE:
Core cutting machines are critical for completing the converting process.
These machines are designed to cut the cores that converted material will be
wound around. Core cutting equipment can be either manual or automatic, and is
typically used to cut paper cores in a variety of diameters and lengths ideal for
converting master rolls of material to smaller rolls. The core cutting machines
are built to cut precise measurements to help minimize waste during the
manufacturing process. The core cutting machines offer the perfect solution for
production professionals in all industries.

26
1.5.9. VARIABLE DATA PRINTING – Domino k600i:

Variable data printing is used in barcode printing in the press. The machine
sense eyemark on the printed substrate and print the barcode over the substrate.
Variable Data Printing uses thermographic process of printing over the labels
such as barcodes.

27
 Technical Specification:
Maximum line speed Standard 37.5 – 150 m/min (123 – 492
ft/min)
Maximum line speed Dual 150 – 200 m/min (492 - 650 ft/min)
Print resolution 300dpi - 600dpi - 1200dpi options
Nominal drop sizes 6, 7, 11, 14pl (14pl drop only at reduced
speeds)
Image width range 108mm (4.25”) to 782mm (30.81”)
Nominal media to print head distance 1.0mm (0.04”)
Media Coated and uncoated paper, foil and
plastic
Ink System
Ink Supply 1 - 10 litres (ink dependent)
Ink Type UV Curable / LED Curable / Aqeous /
Foil Adhesive / White Heavily
Pigmented

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1.6.PREPRESS:
The major prepress work over the best labels company is creating the design
layout of the plate and aligned the registration marks over the borders of the
plate. They checks the possible errors in the plate for maintaining the quality and
accuracy of the plate. Adobe illustrator and Adobe indesignsoftwares were used
in the prepress desk. Adobe indesign were used for creating and deciding the
No. of ups in the plate and Adobe illustrator was used for checking the errors in
date, alignment and print control strip was used in this software. The final
design is forwarded for plate creation, As plate creating unit was not available in
the company.

1.7.QUALITY CHECK UP:

The raw materials is checked for Surface quality, Total gsm, Face stock gsm,
Release paper gsm , Adhesive gsm, width, total thickness, Face stock
thickness, Roll outer diameter, Roll inner diameter, Cracks, Wrinkles/creases.
Based on the results, the material is accepted/rejected.

1.8.PARAMETERS CHECK:

The parameters that are checked are Shade card, No. Of ups , Type of
varnish, Type of foil, Text variation, Color variation, Register out, Tape test,
Set-off, Banding mark, Die cut problem, Lamination problem, Matrix removal,
Blade opening.

1.9.JOB TICKET DETAILS:

The job ticket contain Customer name, Job type, Job no., Material,
Size, Cylinder, No.of colors, Order quantity.

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1.10.POST PRESS - DISPTACH UNIT:
In post press, the quality check up is done manually by labours. The
rewinding of offline labels is done manually with a rewinder. The labels are
bundled based on the requirements given by the customer. The delivery data,
delivery address and the mode of delivery is checked carefully over the unit.

1.11.CONCLUSION:
We watch and research the press and post-press departments for the top
labels. This knowledge improves our understanding of flexographic printing,
which we did not even observe on our industrial visit. As a result, this training
enables us to provide real-world knowledge of the flexographic process and the
working conditions at a commercial printing press.

30
 2.1.INTRODUCTION

So far, we’ve studied many theory courses and few lab courses. In future,
we’ve to implement what we studied in these courses in industry that is
printing press. To prepare us to that environmental situation, we’ve the
course “PT5513 INDUSTRIAL TRAINING” with the objective of ‘To
experience and understand real life situations in industrial organizations
and their related environments and accelerating the learning process of
how student’s knowledge could be used in a realistic way’.

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 2.2.COMPANY PROFILE
The Times of India Press is one of the top newspaper printing
industries in India. The Times of India, Chennai Press Division is
located in Sholinganaullur. It is owned and published by Bennett,
Coleman & Co.Ltd. (B.C.C.L.). It offers the best in color printing.
The Times of India has won the prestigious International Newspaper
Color Quality Club (INCQC) award given by WANIFRA, the World
Association of Newspapers and News Publishers. This plant consist of
eight web offset machines in stack press model which is connected
with two superstructure folders which can accommodate 32 pages of
printed newsprint individually. Manrold branded web offset machines
are planted whose specification can be elaborated as double width
single circumference sized blanked which can bear 8 plates at the
same as it is blanket to blanket method of printing. Size of the single
plate is 575mmx347mm and panaroma plate is 575mmx696mm. Plate
cylinder can bear four single plates or two panaroma plates normally.

32
 2.3.PRODUCT RANGE

1. The Times of India

2. The Economics Times
3. Chennai Times
4. Times NIE

33
 2.4. SUBSTRATE RANGE

As we noticed and observed reels stacked for printing, we come to know

the basic size variation of reels for the required newsprint size. For example
width of broad sheet is 13.75” which is run as double sheet with the single
width or tetra sheet in the double width web offset machine implanted in
Times of india Chennai plant. Here the substrate range varies from 13.75” to
the maximum size of 55” for the newsprint to be printed in double width
single circumference Manroland Regiomann machine implanted.

2.4.1. Types of substrates on the basis of width :

Types of Width (in

substrate inch)
AX 55”

BX 41.25”

CX 27.5”

DX 13.75”

IX 48.125”

KY 43.3”

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2.4.2.SUBSTRATE RANGE DEPENDS UPON THE
BRAND:
 Aspex - 42 GSM - 1397 mm width - 55”
 JSC Kondopoga ppm
i. 42 GSM - 1100 mm width - 43.3”
ii. 42 GSM - 1222 mm width - 48.125”
iii. 42 GSM – 1048 mm width - 41.25
 Jeonju paper
i. 42 GSM - 1397 mm width - 55”
ii. 42 GSM – 699 mm width – 27.5”
iii. 42 GSM – 1048 mm width – 41.25”

 Papiers white birch - 42 GSM - 1397 mm width - 55”

 Emami – 45 GSM – 1397 mm width – 55”
 Heinzel paper – 42GSM - 699 mm width – 27.5”
 Kruger – 40 GSM – 1222 mm width - 48.125”
 VPM NewsC – Jamsan kuski – 42.5 GSM – 699 mm width – 27.5
 FF soucy WB LP – 40 GSM – 1222 mm width – 48.125”
 Resolute News - 40 GSM – 699 mm width – 27.5”

2.4.3.TYPES OF NEWSPRINT:
1. SNP- Standard News Print
2. GNP-Glazed News Print
3. HQCP – High Quality Coated Paper
4. Hybrid Paper
5. Pink Reel especially for Economic times edition

35
 2.5. INFORMATION TECHNOLOGY

The term information technology is correlated with the process of

sharing and receiving information even from remote areas and networking
the whole area. Networking is the process of conjoining various process
takes place in the industry or work field. Various IOTs and machine
learning processes are get evolving nowadays to ensure proper networking
that improves the efficiency of labours and working ways. A network is a
system of interconnected devices that can communicate with each other and
share hardware and software. It is the backbone of a successfuldigital
workflow. Here the information technology domain is classified into
different categories based on their application and requirements.

36
2.5.1.CTP NETWORKING:
 Normal PDF in the BITS software is converted to TIFF using RIP
server.
 Both the TIFF and normal PDF is stored in Press Manager 1,2.
 These are connected through leased line.
 Two types of leased line are used: 10 MBPS BSNL and 14 MBPS
TATA.
 Leased line is secured and point to point line. Data will not be taken
by other. Data will not be theft.
 WOBE software works through switch, internet cables and router.
Router moves the page from one point to another point through
leased line.
 KVM (Keyboard Video Mouse) switch is used to operate WOBE
clientand main WOBE server.

 CTP machine has one system: CTP software. This has a TIFF
blaster,Page buffer unit (PBU) and Netlink.
 Digital command is used – 1 for image area and 0 non image area.
This command route the laser to blast the TIFF.
 Netlink creates an interface between user and CTP.

37
 2.5.2.PRESS INFORMATION TECHNOLOGY:

PRE PRESS SOFTWARES:

 Various softwares like indesign and illustrator used in editorial

domains are also known as front end information technology.

 They send a document in TIFF and pdf X format which is

received by the press using Dedicated or leased line server

which employs the secure transmission of document by the
encoding encryption technology
 Thus the process is initiated and production process gets

involved

BINO SOFTWARE:
 This software engages with the plate making process whose

primary motive is to regulate the ink usage especially reduce the

Cyan, Magenta and Yellow colour ink usage.
 It is working with the algorithm of GCR theory, Grey colour

replacement theory that correlated the grey colour with the

regular density of all three colours when combined in equal
density and ratio.
 Thus it improves the ink efficiency in Newsprint production.

38
PPM SERVER:
 PPM server is the administration of machine network.
 It is attached with CTP WOBE software.
 Through PPM lock, machine error status can check.
 Printing job can be assigned.

PCOM SERVER:
 PCOM server is attached with machine.
 It connects with all print units through network.
 Each print unit has UC 100.

BAUDIS PC SERVER:
 It is used to monitor print unit motor temperature.
 It is used to monitor current voltage.
 It is used to monitor drive current voltage.
 It is used to check motor and drive levels.

ADS SERVER:
 It is used for turbo calibration.
 It is used for ink calibration.
 It is used for error checking.
 It is used for modules checking.

39
FERAG DESPATCH SYSTEM:

RMD ( DESPATCH SECTION):

 LIM server
 DIM server

LIM SERVER:
 LIM means line master software.
 LIM server is a bundle parameter.
 It decides how many bundles to be dispatched.
 Job manifesto file is copied in this LIM server.
 It is used to print customer information.

DIM SERVER:
 DIM server is a dispatch manager.
 It is used to dispatch the bundle.
 It assigned the bundle to the bay like bay1, bay2, bay 3.
 It is used in glue monitoring system.

40
2.5.3.GENERAL IT :

ADAM LPS SERVER:

 Two servers are present:
o Local
o Central
 Production report is entered here.
 It is used to check Last Page Received Time (LPRT).
 It is used to link Industry 4.0.
 It is used in SNP/GNP checking.

EPABX (ELECTRONIC PRIVATE AUTOMATIC BRANCH

EXCHANGE):
It is used for intercom & outgoing line purpose.

FILE TRANSFER PROTOCOL SERVER (FTP):

 FTP is used to transfer CTP file in case of leased line down.
 It is connected with mobile.
 It can be accessed through Wi-Fi and private network.

DOMAIN PC:
It is attached with timesgroup.com server.

41
LEASED LINES OR DEDICATED LINE NETWORKS :
100 MBPS INTERNET TATA LINE:
 It is used for heavy download.
 It is used in LIM and DIM server.

1 MBPS INTERNET TATA LINE:

 It is used for ferrag machine.

PRIME APP:
 Maintenance is done through Prime App.
 It is used to check schedule.

VPN ( VIRTUAL PRIVATE NETWORK):

 Remote access is done through VPN.
 Through Netscope, we will get the access.
 VPN will work in out of times network.

42
 2.5.4.ELECTRICAL INFORMATION TECHNOLOGY
EMS SERVER:
 Meter is connected to the EMS server through Ethernet cable.
 Each cable has two components.
 Electrical component
 Electronic component
 Generic mail (automatic mail) is generated every day. It is
generated by Times Group.
 It is very useful to calculate consumption so that waste
generated can be controlled.
 Line master is used to insert customer data
 DIM also known as dispatch manager that governs the
dispatch system power consumption and usage
 Main line meter is 33 KILO VOLTS. Through gateway,
we can check the power.
 The electrical meters and centralized with Mumbai plant to
govern the efficiency of the press run in this plant.
 DG1 & DG2 generators are used in case of power cuts.

43
 2.6.CTP (COMPUTER TO PLATE)
CTP Technology allows digital data direct from the computer to
guide lasers in the direct imaging of a plate by using It greatly reduces
mechanical concerns such as registration problems and dot gain and
produces high- quality plates.

BITS SOFTWARE:
The final newsprint layout in the PDF file format is viewed in BITS
(BCCL Intelligent Transmission system) software.

BCCL RIP SOFTWARE:

The RIP converts PDF file format into a format that a printing device
can understand. It is being used for processing PDF files to convert in to
CMYK separations.

RIP WORKFLOW:
1. Input PDF
2. Define Screen Type : Frequency Modulated (Dot frequency
controlled) - Dot size - Fine/Medium/Course
3. Select Resolution – 1016/1200
4. Apply Plate calibration curve:
Plate calibration curve is being applied to compensate the dot gain on the
plate. Basically it is being applied to linear the plate i.e. 50% dot value in
the soft file can be produce 50% dot value on the plate.

44
 5. Apply Intended Press curve:
Intended curve is being applied as standard dot gain on the printed samples.
Actual printed dot gain must same/nearby to intended values. Intended
press curve can be standard as per machine capabilities.
6. Actual Press curve:
Actual press curve is nothing but measured value of printed samples. This
value has to be nearby/matched values of intended press curve.
7. Final TIFF output – CMYK

WOBE SOFTWARE:
 It is used to edit and check TIFF file
 Check the deadline, image quality, price and imprint
 It can do page planning and send it to the output device like CTP1,
CTP2.

CTP PLATE:
 Violet photopolymer CTP plate is used.
 Photopolymer plates are aqueous processing, light sensitive,
negative working plates with dimensionally stable, pretreated
aluminum base.
 Plates are coated with dye sensitive photopolymer that is readily
affected by the light energy.
 The plate thickness is 0.28mm.
 Plate size: 347 × 575 (single), 696 × 575 (panorama)
 With one plate, we can print maximum 3.5 lakhs copies.

45
CTP COMPLETE PROCESS STEPS:
 Krause LS Jet- Image setter
 Hasse - processor
 Nela – bender

CTP MACHINE – KRAUSE LS JET:

 The transfer of digital data from the computer to image the plate
surface is performed by the Krause LS Jet, the plate image setter.
 Sections of LS Jet:
 Feeding section
 Exposing section
 De-loading section
 Major components of LS Jet:
 Laser
 TIFF blaster
 Optics unit
 Polygon
 Imaging Bed
 The plate is loaded in the plate trolley unit and feed to the exposing
unit using plate lifting.
 Once the plate move towards the laser, the protective sheet placed
onto the plate is removed and is collected in the bin separately.
 Air compressor is 7 bars. This is used to life the plate from the trolley.
 In flat bed exposing bed, the laser beam deflected line by line across
the plate by a rotating polygon mirror with imaging and correction
46
 optics.
 Speed: 300 plates/hr.

HAASE PROCESSOR:
 The purpose of the Plate processor is for the processing of
onesided offset plates which uses technova replenisher for
developing process
 Roller diameter: 79.5 – 80
 Roller hardness: 35
 Brush Pressure setting: 350gm to 450gm using a 10cm width of
1 micron strip.
 It is responsible for the processes that have to be done after the
plate has been exposed that have to restrict further exposure to
the normal light and during plate handling techniques.

PROCESSING SECTIONS:
 Pre-heating - Image area is strengthened and hardened,
optimum heating temperature – 135 -140o C
 Pre-washer - Unwanted particles are removed via washing
 Developing - Non-image area gets removed.
 Washing – Plate is rinsed to ensure proper removal of non
image areas
 Gum Finishing – Produce uniform background and
desensitize the plate by using Technova unifin Gum which is
mixed with water in proper proportion.
 Drying – Plate is dried from the both sides.

47
 NELA BENDER:
 It is computer control
 Optical lens catch the plate and automatically sense and bend
the plate.
 Leading edge of the plate is bended as same as normal offset
plates but the tail edge is bended twice to hold the plate cylinder
firmly.
 The the plates are stacked besides the conveyor belt located just
right of bender

PROBLEMS THAT TAKE PLACE IN CTP:

 Color mixing
 Software related problems
 Plate Jamming
 Bender working

48
 2.7.CONSOLE UNIT
PPM SETTINGS (TOWER, FOLDER):
 Standard job/ Mixed job
 Folder
 Former
 Tower
 Page setup

PCOM SETTINGS (MACHINE COMMAND/EXECUTION):

 Job name – click and load
 Tower configuration
 Pre settings
 Ink
 Water
 Component(cutting)
 Partial web
 Ink keys adjustments to colour match the newsprint design
 Color registration
 Buzzle wheel – Push or pull to control the Fan in and Fan out in the
paper edge.
 Circumference: 3mm; Lateral: 2mm;
 Reel stand
 Record the machine – Alarm message
 Water/Ink curve – speed and quantity
 Run sequence 1,2

49
 2.8. MAKE READY OPERATIONS
1. Check Technotran and Chiller ON
2. Check Ink Pump ON
3. Check Blanket Condition
4. Check Turner Bar Light Barrier acknowledge
5. Check Ink Duct Dummy area
6. Check Folder settings
7. Check Ink Presetting ON
8. Check Damp water PH & Conductivity
9. Check Glue Position and condition
10. Check Plate all fixed or Not
11. Check Turbo water supply and Electrical connection
12. Check ZIP values loaded or Not
13. Check web path
14. Check Quadtech, Cut Con and Camera Position
15. Check Tension preset values as per pagination
16. Check Bustle wheel Preset value
17. Check Mailroom Machines are ON
18. Check Reel stand Operator readiness
19. Check and clear any red indication errors in the centralized
Annunciator
20. Check Cut off Preset values for New product
21. Check Reel stand in Auto or in Manual
22. Check Ink train coupling ON
23. Check Slitter ON or OFF

50
2.9.PROCESS WORKFLOW
The Workflow consists of three sections:
1. Input
2. Process
3. Output
INPUT:
 Paper of needed width and required quality
 Ink of required properties like optimum viscosity and density
 Plate of optimum quality that should be durable and viable for
newsprint in lakhs
 Water especially for dampening and machine cooling purpose
that have to be included after the water treatment process

PAPER:
 Paper is a thin sheet material produced by mechanically or
chemically processing pulp of wood or other fibrous materials.
 Paper is anisotropic in nature which implies different properties in
different directions.

PAPER MANUFACTURING PROCESS:

 The paper manufacturing process has several stages –
 Raw material preparation and handling
 Pulp manufacturing
 Pulp Washing and Screening
 Chemical recovery
 Bleaching

51
  Stock Preparation and
 Papermaking.
 Paper production is basically a two-step process in which a fibrous
raw material is first converted into pulp, and then the pulp is
converted into paper.
 The harvested wood is first processed so that the fibers are
separated from the unusable fraction of the wood, the lignin.
 Pulp making can be done mechanically or chemically.
 The pulp is then bleached and further processed, depending on the
type and grade of paper that is to be produced.
 In the paper factory, the pulp is dried and pressed to produce paper
sheets.

REEL:
1. Reel form: Paper wound on a core of any size.
2. Higher diameter reels help in reducing number of splicing and
improves productivity by avoiding abnormal breaks during reel
splicing etc.

REEL DEFECTS:
1. Starred Roll:
 The outer diameter wound more tightly than the inner core.
2. Core Damage:
 Core is ground up inside because of shaft.
 Damage caused by poorly designed shaft.
 Poor mechanical strength of core.

52
 3. Edge cracks:
 Uneven caliper/ strength.
 Slitter setting at the mill
4. Reels with joints:
 While jumbo reels gets slitted and rewinded into the reels of
required size, to compensate the complete size, some joints are
produced using calendaring process that may lead to web break
when they run through the press.

INK:
1. Ink is the dispersion of colorants in the vehicle/ medium.
2. Ink contains:
• Varnish: 60-80%
• Color: 15-25%
• Oil: 5-10%
• Additive: 2-5%

FUNCTIONS OF DIFFERENT RAW MATERIALS:

Pigments:
 Pigments are particulate matters that are insoluble and
essentially not affected physically and chemically by the media
in which they are dispersed.
 Pigments are basically used to provide colour in printing inks.
 Function of Pigment:
1. Optical: Color, brightness, gloss, opacity/transparency
2. Protective: Flexibility, weather resistance, toughness, water
resistance.
3. Reinforcing: increase the strength of binder, provide

53
 heat and light fastness, fastness to bleeding.
Varnishes:
 Varnishes are heart of printing inks.

 Varnishes are the combination of resin, Vegetable oils,

petroleum distillate and additives.
 Selection of Varnish depends on:
 The Printing process

 Speed of Printing

 Substrate Being Printed

 Drying Mechanism
 Function of Varnishes:
 Pigment wetting and thereby assist pigment dispersion.
 Varnishes impart Gloss , Rub, Flexibility , Adhesion
and Resistance property to the Finished print
 To aid the transport of Coloring matter on to the
Substrate
 Incorporate printability to the Ink-Film
 Bind the pigment to the Substrate surface so that the
final print dries to form the film

Additives and their functions:

 Anti-Oxidant
 Provide duct freshness to inks
 Prevent surface skinning eg.- Hydroquinone , BHT
 Waxes
 Improve rub resistance

54
  Slip
o eg- PE, PTFE
 Driers
 Catalyst to promote drying throughout ink film. eg.-
Co, Mn,Ca,Zn octoate / napthnate
 Others
 Thixtropic agent – increase viscosity
 Hydrophobe– reduce emulsification
 Surfactant : reduce surface tension

Functions of Oils:
Vegetable oils:
 Contribute to gloss
 Increase Solubility
 React with driers to form film through an oxidation reaction
 Generally slow down the setting in S/F inks and heat drying
in H/S inks
Petroleum Distillate:
 Control setting in ink
 Used as a rheology controller
 Reduce gloss if used in excess

55
 PROCESS:
 Coldset Web Offset Presses is used here for Newspaper
production.
 In this process, the ink dries by absorption and UV penetration
into the underlying paper.

PROCESS STEPS:
 Reel Stand
 Printing unit
 Turning bar
 Folder
 Bundle unit

Reel Stand:
The main tasks of a reel stand are:
 to unwind the paper reel
 to tension the paper web and keep it at constant tension and
 to change the reel fully automatically

Autosplicing technique :
We learnt and observed the autosplicing process which consist of
the basic components namely 3M tape, brown cellophane tape, silver
pattern tape, loaded reel in chuck of reel stand whose function depends
upon the principle of pneumatics along with all other sensors feedback
mechanism.
The process can be explained with the kite and first reel which

56
initiates the leading process of the reel. After the first reel has been
loaded, next reels are made ready for the autosplicing process by the
procedure
 Reel is inspected for the damages and damaged sections are
cleared using the gadget or instrument called scooper as
same as scissor
 Then flat edge of the reel is marked with double side 3M
tape and silver pattern tape is sticked just above it
 3M tape is employed to stick with the existing reel
especially for splicing because it have to be pasted with the
reel that almost be ended
 Silver pattern tape is employed along with the sensor that is
placed behind the reel stand that sense the upcoming reels
lead and actuate the knife and sponge roller to cut the
existing reel at the same time of pasting operation which is
influenced by 3M double side sticky tape.
 Thus the autosplicing process is initiated and completed in
the printing machines or in individual towers
 Mostly this process is controlled by sensing reels diameter
which is diameter sensing sensors role. Thus the existing
rolls minimum diameter is adjustable from 120 to 150mm
range
 When that minimum diameter is attained thus the
autosplicing process is started.

57
Inking System:

S.NO ROLLERS DIAMETER HARDNESS

1 Top Ink transfer roller 120 mm 28-36
2 Bottom Ink transfer 120 mm 28-36
roller
3 Outer form roller 114 mm 30-35
4 Inner form roller 105mm 30-35

Dampening System:

S.N ROLLERS DIAMETE HARDNES

O R S
1 Damp Transfer 120 mm 20-27
Roller
2 Damp Form Roller 114 mm 20-27

 Life of the Rollers is 4 - 5 years depending on the running

condition.
 If diameter reduces by 2mm, then the roller has to change.
 If hardness goes up to 30, then the roller has to change

Printing Unit:
 The Printing towers consist of four printing units to print Cyan,
Magenta, Yellow and Black ink onto the newsprint.
 The newsprint web travels upwards in the printing tower during
the ink is applied to it on both sides of the reel.
 The press consists of several towers many more pages can be
printed at once.
58
Plate cylinder:
 For every page there is one individual printing plate per color.
 This printing plate is mounted onto the plate cylinder within the
printing unit.

Blanket cylinder:
 The ink is transferred from the printing plate to the substrate indirectly
via the blanket.
 Blanket cylinders are generally non-bearer type for high speed
machines.
 Two blankets are fixed onto the cylinder.
 There is no metal backing.
 Squeeze pressure is the pressure exerted between two cylinders such
as plate cylinder and blanket cylinder or between blanket to blanket. It
is used in dot gain determination.

Blanket specifications:
 Length : 1118 mm
 Width: 705 mm
 Thickness: 1.93 mm
 Leading edge: 60°
 Trailing edge: 120°

59
Impression cylinder:
 The impression cylinder provides a hard backing which allows the
blanket to press a strong, solid impression on the paper.

Turning bar:
 Turning bar has two operations: Slitting and Turning
 It is used to slit the pages into two.
 And then, overlap the one slit half of the web from one side to the
other.

Folder:
 Folder contains three cylinder:
 Cutting cylinder
 Collecting and folding cylinder
 Jaw cylinder
 The Newsprint web is cross-cut with the knife of a cutting cylinder.
 The cutting cylinder moves against a cutting bar on the tucker blade
cylinder.
 The front end is held on the tucker blade cylinder by pins so that it
follows the latter.
 Then it is fold both in longitudinal and lateral direction by Folding
and Jaw cylinder.

60
Bundle Unit:
 The copies are collected on the delivery belt and usually transported to
the mailroom using a gripper conveyor system.
 Newspaper copies can be bundled directly so that they are ready to be
put into a truck for transportation.

OUTPUT:
This process leads to get the massive output from the press called
NEWSPRINT, which plays a vital role in gaining knowledge of this world.

61
 2.10.INNOVATIONS
The press division of The Times of India has gone through
several waves of innovation. Some of the well accepted and commonly
used ones among themare Flaps, Bookmarks and Seamless printing.

BOOKMARK:
Its is special innovative technique which grabs attention same as
front page add as it is left released from the width of the paper more
commonly 1.5” which is especially run in KY reel whichs size is 43.3”.
Thus it experience the same interest from the customers side.
Bookmark ads peek out of the newspapers just like a normal
bookmark marking the page where the ad has appeared. Bookmark ad gets
printed in special reel so called KY which has width of 43.3 inch around 1.7
inches greater than BX reel.

FLAP:
Nowadays flaps are placed anywhere inside the newspaper
thereby confounding one completely. It has given `news on the margin’ a
new twist by printing important analyses literally on the edge of a flap.

FRENCH WINDOW:
This advertisement technique is really innovative and is in great
attention grabbing in front of readers as its same as conventional French
fold. In which single ad is displayed in the front page with the slitted
opening in the centre and the contents are also added on the second page
with its alternative side.
62
JACKET FULL PAGE AD:
These display ads are placed on the Front Page of the newspaper
on both thesides.

HALF JACKETS AD:

These display ads appear on half of the front page in a
newspaper.

POINTERS AD:
Pointer ad appears on the left-most column of the main page.

Masthead:
These ads materialize under the masthead of the newspaper in the
main page.

GNP:
GNP is also known as glazed newsprint which uses glossy high
grammage sheet in the front page to grab more attention towards that
adverstisement. Rarely last page also gets printed with GNP as in the case
of editorial need to be displayed fullfinished. GNP can only be printed in
Tower 1 of line 1 and tower 5 of line 2. So that GNP advertisements are
printed in some special brand reels like RR papers with the width of
27.5”which is slitted and rewinded from AX sized 55” reels as per the
requirement.

63
CENTRESPREAD:
In this innovative method, advertisement gets printed in central
double broadsheet as the same image without the gutter space by using
panaroma plate. It enhanced the readers mind thought and also grabs
attention of the consumers Thus this innovations plays a great role in this
industry.

SEEMLESS:
It is same as the centerspread but gets printed in some other
sheets of the newsprint other than centre page which also seems same as the
single image continued from the left end to the right end of the complete
newsprint.

64
 2.11. UTILITY SYSTEM
1. Water
2. Power
3. Air conditioning
4. Air compressor

2.11.1.WATER:
Water is treated according to industrial needs. Waste water
treatment is subdivided into 2:
 Sewage treatment plant (STP)
 Effluent treatment plant (ETP)

MAJOR STEPS INVOLVED IN TREATMENT OF WASTE WATER

ARE:
1. Passage of water through sand filters and activated carbon filter
 Sand filters are used to remove sand and dust from water.
 Activated carbon filter uses charcoal and removes iron
content and bad odour from water.

2. Passage of water through softner plant

 When water passes through softner plant, it removes the salt
that settles in water. It retains Sodium (Na) resins. When
water is passed through the softner, it is converted to sodium
based. After sodium gets over in the softner, it us treated with
NaCl (brine solution)
 PH, hardness and conductivity are the important parameters
65
 to be considered in water.
 Techno trans maintains the correct amount of pH, hardness in
water.

Use of the treated water:

 Most of the treated water is used for gardening purpose
which constitutes 1:2 of the total treated water level.
 Treated water is also used in air conditioning medium.
 It is used in places where heat is exchanged by using water as
a medium of exchange.

2.11.2.POWER:
Electric power is the primary and essential need for the press run. Electric
power is provided in two ways namely from the electricity board and using
Diesel generator.

ELECTRICITY BOARD :
 33 KV current is provided using High tension EB line to the
mini transformer set up in the plant externally by the board
 That outlet power is connected with incomer to supply it to the
plant’s electricity control panel.
 Two power supply cables are present upon which one of them is
leave undisturbed as it supplied power to the old machine
 New line is connected with three parallelly connected VCB
vacuum circuit breakers.
 Earth fault relay and over current realy in the VCBs are
responsible for the automatic power shutting down properties

66
  One of the VCB is connected with one of the two step down
transformers which are also set up for the backup purpose
 In the step down transformer 33KV current is stepped down into
440V,50 Hz current which is then supplied to the whole plant
using several sub distribution panel.
 Step down transformers are placed on chip down stones to avoid
earthing problems
 On load top changer is used to adjust the voltage level if needed
 Thus the power is distributed all over the plant from the power
provided by EB

DIESEL GENERATOR:
 Diesel Generator is also called as DG which is set up to
provide power supply when there is any power issues for
the backup purpose
 There are two DGs which are ideal and maximum fuel
capacity of DG is 1200 L individually.
 They can provide power for the whole plant as same as
the power produced by EB power
 It has the maximum efficiency of producing 3.5 KWH of
power per litre of diesel consumed
 Scrubber technology is implemented to avoid carbon ash
emission from the DG
 Batteries are used to kick start the generator initially.
 It produces the current with 440V, 50Hz that can be
supplied to the plant without any step down processes

67
  It could consume upto 250 L of fuel per hour for the
average optimized load run in the press.
 Thus the power is supplied as same as before using
various sub distribution panels to the machines
E - MAINTENANCE:
 Transformer oil filtration process is maintained annually
 Relay test is done in VCBs for the regular periods
 Earthing is checked and maintained annually
 Radiator water level in DG is maintained regularly
 Fuel filters and Oil filters are changed in yearly checkup
as per the need

2.11.3.AIR CONDITIONING:
The 4 main parts in an air conditioning system are:
 Compressor
 Condensor
 Expansion valve
 Evaporator

COMPRESSOR
 The compressor is responsible for moving the refrigerant
between the evaporator and condenser coils, ensuring that the
refrigerant changes to gas or liquid as needed.
 It is a device that increases the pressure of a substance (usually a
gas) by reducing the volume of the substance.

CONDENSOR
68
 1. The purpose of the condenser is to receive the high-pressure gas
from the compressor and convert this gas to a liquid.
2. It does it by heat transfer, or the principle that heat will always
move from a warmer to a cooler substance.

EXPANSION VALVE
1. The expansion valve reduces the pressure of the refrigerant fluid
upstream of the evaporator.
2. This drop in pressure cools the fluid, it is then sprayed into the
evaporator.
3. The expansion valve is always attached to the evaporator.

EVAPORATOR
1. The evaporator works the opposite of the condenser, here
refrigerant liquid is converted to gas, absorbing heat from the air
in the compartment.
2. When the liquid refrigerant reaches the evaporator its pressure
has been reduced, dissipating its heat content and making it
much cooler than the fan air flowing around it

AIR COMPRESSOR:
1. Air compressors have a multitude of uses for leisure and
maintenance at home or in businesses to get work done
efficiently and safely.
2. The pressure that comes from compressed air has so many uses.
3. They are designed to provide a steady flow of compressed air for
long periods of time and can take fluctuating surges in use
typical in major manufacturing plants.
4. These compressors are built with high-quality components that
69
allow for customization to the specific environment to improve
performance, energy efficiency and reliability

70
 2.12.FIVE S’ – WORK PLACE MANAGEMENT
FIVE S i.e. Seiri, Seiton, Seiso, Seiketsu and Shitsuke are a series
of steps taken for ensuring proper Organization, Neatness, Cleanliness,
Standardization and Discipline in work place for sustained housekeeping
and management practices. There are five 5S phases. They can be translated
to English as 'sort', 'set in order', 'shine', 'standardize', and 'sustain'.

1. SEIRI:
Seiri is sorting through all items in a location and removing all
unnecessary items from the location.
Goals:
 Reduce time loss looking for an item by reducing the number of
unnecessary items.
 Reduce the chance of distraction by unnecessary items.
 Simplify inspection.
 Increase the amount of available, useful space.
 Increase safety by eliminating obstacles.

2. SEITION:
Seiton is putting all necessary items in the optimal place for
fulfilling their function in the workplace.
Goal:
 Make the workflow smooth and easy.

71
 3. SEISO:
Seiso is sweeping or cleaning and inspecting the workplace, tools
and machinery on a regular basis.
Goals:
 Improves the production process efficiency and safety, reduces
waste, prevents errors and defects.
 Keep the workplace safe and easy to work in.
 Keep the workplace clean and pleasing to work in.
 When in place, anyone not familiar to the environment must
be able to detect any problems within 15 metres (50 ft) in 5
seconds.

4. SEIKETSU:
Seiketsu is to standardize the processes used to sort, order and
clean the workplace.
Goal:
 Establish procedures and schedules to ensure the repetition
of the first three 'S' practices.

5. SHITSUKE:
Shitsuke or sustain is the developed processes by self-
discipline of the workers. Also translates as "do without being told".
Goal:
 Ensure that the 5S approach is followed.

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 2.13. PRESS MACHINE CONFIGURATION
 Manroland Regioman web offset machines is present in Times of
india Chennai plant which specifications can be listed below. It has
four colour units which is mostly common is many presses that
include Cyan, Majenta, yellow and black.
 Perfector type of press that can also be called as blanket to blanket
type of printing is present which can be differentiated as LHS and
RHS from the operator side
 This has the proper feature with respect to the size of plate cylinder
accordingly with the blanket size that gives the machine in four
different types namely :
 Single width single circumference machine which can accommodate
four plates only that can print double broadsheet instantly.
 Single width Double circumference that can hold eight plates and can
print the reel of same double broad sheet width with double the
length.
 Double width single circumference press that can hold upto eight
plates at the same time and can print the newsprint of width 55” reel
which is considered as efficient method of printing.
 Double width double circumference can hold 16 plates in the same
time and can print 16 pages of newsprint within the same tower.
 A completely printed substrate can be got from the unit consist of
four colour sections with 4 bridge and 8 couples that is here called as
tower
 Due to the efficiency and need, double width single circumference
regioman machines are implanted in this plant which can print 8
pages in a single run.

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 Four towers are connected with a single folder that can print and
collate
 32 pages of newsprint instantly. Two sets of folder groups are
available so 32 pages of newsprints can be printed individually
 Namely Folder A is combined with Tower 1,2,3 and 4 and Folder B is
combine with Towers 5,6,7 and 8. Thus the machines are set up and
process can be explaine as follows.
 The reel for the specified job is selected from the sizes ranging from
55" to
 13.75 and other sizes. The reel is placed in the reel stand within the
arms. The Chuck's in the arm holds the reels.
 The Chuck's can be adjusted using the arrow keys on each arms. The
kite is attached to the reel for loading the reel to the printing unit and
till the folders. High speed splicing method is used to change the web
when the loaded web reached the diameter of 125 mm.
 A new reel is attached to the opposite side of the arm. A pattern tape
and 3M tape is attached to the web start area for identification of
sensor and accurate splicing at the high speed. The loaded web start to
rotate at the speed of the old web. When the loaded web gets into a
synchronised speed, the cutter blade cuts the previous web and the
sponge wheel gives pressure to the both web accurately and the web
gets attached to each other. Next, the dancer roller assist and controls
the infeed pressure of the web.
 The pressure over the dancer roller is 90m/s. The infeed pressure in
the web is 290m/s.Next, in the printing tower, the web passes within
the cyan, magenta, yellow and black bridges.
 Blanket-over-Blanket printing method is used in the printing process.

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 A bridge consists of two couples. Each couple consist of a blanket, a
plate cylinder, inking unit and a dampening unit. The blanket cylinder
consists of two blankets of dimension 1110x700.
 Each couple has four blades. The inking can be controlled for each
blade using the ink keys. The dampening can be controlled by the flap
in the dampener unit. The registration is adjusted by the lateral and
circumferential movement of plate and blanket cylinder respectively
using the register motors with the cylinders.
 The blanket is also used as a tension control to the web. As the
blanket is used for a long time, the blanket losses it's tendency to
provide the tension and it normally passes the web which increases
the tension over the lead area of the tower. In the press, sequence 1 is
used for cold start and sequence 2 is used for warm start. The
sequence follows with the starting of dampening unit, followed by
dampening rollers, inking rollers, impression and the inking unit and
finally the registration.
 A time delay of 5 seconds prevails between both the sequence. Cold
start is used for the fresh start of the press. Then, the image is
transferred in the sequence of cyan, majenta, yellow and black
respectively.
 A buzzle wheel is present between the majenta and yellow units to
compensate the msiregistration caused due to long distance between
those units. The buzzle wheel over the blade 2 and 3 is slightly
backward of the buzzle wheel 1 and 2. As the elongation of the web is
higher over the edges. As the web passes the black bridge, a drift
roller is used to provide an additional tension of 1% to the web which
provides appropriate tension over the printing area. The drift roller is

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 present on top of each tower.
 Next, in the lead region, the webs are transferred to the folders. The
webs are slitted in the required page dimension and stacked one over
the other. In the slitted web, a part of web is passed straightly to the
folder which is called straight web and the other web is stacked over
or below the straight web, using a turner bar.
 The front page is placed in the bottom for folder A and in the top for
folder B. The RTF (roller on top of forme) which provides additional
tension of 5% to all the web attached to the folder. The folder
contains two forme, bottle roller, jaw cylinder, tucker blade, diameter
cylinder. The jaw cylinder is responsible for the second fold of the
web. The blade over the cylinder cuts the web with high speed which
results in accurate cutting of the web. Next, the pins holds the
newspaper and transfers it to the next cylinder. Folder A consists of 8
pins and the Folder B consists of 6 pins which is used for the
identification purpose. As the papers passes the jaw cylinders, it is
transferred to pneumatic grippers and finally, the newspapers are
transferred to ferag, the dispatch system.

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STRUCTURE OF FOLDER ALONG WITH ITS TOWERS

FIG. 13.1 MANROLAND REGIOMAN MACHINE STRUCTURE

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 2.14.PRINT PROBLEMS AND RECTIFICATION
Printing process is not only about reproducing the image in desirable
quality but also about problem handling process while the machine running. There
are several problems arises while the press running is in progress which have to be
noted and encountered as soon as possible to reduce the wastage and to get
desirable product in required quality. Problems can be happened due to various
circumstances like due to ink variation, pressure variation, web tension variation,
environmental condition, process variation and substrate variation. Those problems
are handled through well developed skills and experience got by operators and
heads of the machines manually and also by feedback mechanisms evolved in the
highly updated machines automatically. Some of the common print problems arises
in newsprint industries are listed below with their rectification techniques.

GLAZING:
The buildup of ink pigment particles in the surface of the ink rollers,
which provides a glaze effect on the surface of the ink rollers.

RECTIFICATION:
The glaze problem can be rectified by basic washup technique and
usage of cleaning solvent.

CREASING:
Creasing is the problem caused by the folding of the paper during the
passage between the rollers. Web expansion increases the creasing effect on the
paper.

RECTIFICATION:
Creasing can be rectified by proper alignment of machine and rollers
and accurate web tension over the web.

DOUBLING:
Doubling is the duplicate of impression out of register caused by the
premature contact of the paper and the blanket before the true impression is
made.

RECTIFICATION:
Doubling can be rectified by reducing the pressure, adjusting the ink
feed and dampener setting.

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HICKIES:
An irregular or donut shaped white spot on the printed surface is called
hickies. It is caused by weak fiber strength or accumulation of dried ink
particles, dampener cover particles over the blaket and plate cylinder.

RECTIFICATION:
Hickeys can be rectified by frequently cleaning the covers particles,
checking for contamination in the ink and the fiber strength of web.

SCUM:
Scum is the problem arises due to accumulation of high level of ink on
both image and non-image areas. The non-image areas become receptive to ink
which reduces the image quality in huge manner.

RECTIFICATION:
The scumming can be rectified by adjusting the ink film, usage of
good plate cleaner.

WEB BREAK:
Web break is the most important problem which can be defined as the
breakage of the web during the transfer between the rollers in the printing unit
while the process is going on due to various process related circumstances. For
example, it is also caused by the improper tension in the rollers or sticking of
web one over the other.

RECTIFICATION:
Web break can be rectified by the proper alignment of rollers,
reducing the pressure in the web and by doing some more processes.

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 2.15.PRINT WASTE ACCUMULATION AND
DISPOSAL
Waste accumulation is common in all the printing process which is
commonly due to damages caused in the substrate during the transportation. Most
commonly outer layer of the substrate is teared off and considered as waste as it
cant be used completely in the press. Especially in the newsprint industry waste
accumulation is high as they use recycled papers in great manner and their initial
trial speed is also much more than speed of commercial presses due to their high
speed production time and target. Due to this circumstance, newsprint waste
can’t be implemented for recycling process completely. Newsprint wastes
accumulated daily and their impact is lesser than commercial industries but they
need to be considered as given below.

NEWSPRINT WASTE:
Newsprint wastes are broadly classified into two broad categories namely
 Non process waste or unprinted substrate waste
 Process waste or printed substrate waste

UNPRINTED SUBSTRATE WASTE:

 Transit waste which can be elaborated as wrapper material used to

cover the reel and side disc used to protect the reel laterally.
 Reel Handling waste can be defined as wastes due to transportation
problem and pressure impacted while stacking the reels.
 Tear-off waste are most common in all type of presses as the outer
layer is teared and thrown off
 Reel end waste or core waste which is different in web presses than
in sheet fed presses because reel of paper means continuous roll of
paper is rolled over the centre hollow cylinder like substance made of
cardboard like material that is called as core upon which some level
of sheet of paper is left unprinted due to the wrinkles near the core.
 Web waste due to waterlogging that may cause due to the AC vent or
water dropped on reels lateral side when stacked in the store room

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PRINTED SUSBTRATE WASTE:

 Trial print waste is common in every printing processes as error

and correction method is in practice conventionally
 Mis registered substrate is the most important problem in
newsprint industry as the low grammage substrate is used in
newsprint. It may causes due to elongation of substrate while
adjustments are being done in dampening unit of the press.
 Error found substrate / newsprint can be defined as the instant
error arised in the press may lead to rejection of particular
segment of printed newsprint and they gets disposed as waste.

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2.16.OUTCOME
Industrial exposure of how newspaper printing is done is known.
From CTP plate making to Delivery unit, all the process and
technology involved is learned. We are able to gather a lot of
practical knowledge about Newspaper production. We practically
understood the theoretical knowledge on the subjects which were
taught in the previous semesters.

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 3. SAFFIRE OFFSET PRINTER

3.1. COMPANY PROFILE

The Safire Offset Printers is One of India’s Leading State of
the art commercial colour printing firms, located in Sivakasi, the
Printing Capital of India. Having carved a nice for itself as a high
quality and reliable printing house, The Safire Offset Printers has
emerged as the ultimate printing destination for those who value,
optimum impact compelling graphic design, absolutely competitive
pricing, and deadline requirements.
With a highly satisfied and loyal client base of more than 3000
reputed companies, spread across India and abroad, The Safire Offset
Printers has revolutionized the world of commercial printing by
combining certain forms of conventional skills with the latestcost and
time spent on films. Coupled with an exceptional workforce,
numbering more than 500, the extensive range of machinery has
enabled The Safire Offset Printers to attract large volume printing
clients, ever since its inception. The proof of The Safire Offset
Printers total commitment to its valued clients and the
professionalism is reflected in its ever expanding all India network.

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3.2 PRODUCT RANGE
The product range of the industry includes the following
structure has mentioned:
 Books
 Booklets
 Business cards
 Invitation cards
 Diaries
 Bookmarks
 Calendars
 UV coated products

3.3 SUBSTRATE RANGE

The common paper standards used in the campany ranges from
the paper stocks in companys of ITC, TNPL, GMG. The common
paper sizes are:
 58*91cm
 51*76cm
 102*76cm

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3.4 PRE-PRESS
The softwares used in the prepress department are adobe
indesign, Coral draw 11, Adobe photoshop, Adobe illustrator.

The workflow in the prepress department

Work flow
Original file from customer

Pre-press Department

Raster checking

RIP

3.4.1. PLATE MAKING PROCESS

Depending on the work they are intended for, various kinds of
plates and processes. The various types of plates used are:
 Thermal plate
 PS Plate
 Wipe-on Plate.

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3.5. PRESS
3.5.1. MACHINES AND THEIR SPECIFICATION

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3.5. POST-PRESS

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