2. PREFACE
The practical studies gave us a chance to analyze the work of industry. So
we have come to know that the difference between theoretical and practical aspects
and better management knowledge for a smooth management of an industry.
The PGDM program provides students with a fundamental knowledge of
business and organizational function and activities as well as exposure to strategic
thinking of management. It is the essential part of any managerial programs like
PGDM. So our visit was at AARPEE PACKAGING.
The score of the report is limited to an analysis to company in the light of
“production management”. But the main thing is that it helps in building our
communication skills, which is the basic necessity in field of life.
2
3. ACKNOWLEDGEMENT
The main intellectual idea for making this report is to clarify the functioning
of industries. With immense pleasure, would like to thank AARPEE
PACKAGING.
We feel honor to thank our patron and Prof.GURMEET SINGH SIKH for
giving us an insight, his valuable time, timely suggestions and constant support
throughout the project. We are highly thankful to the staff of AARPEE
PACKAGING for their cooperative nature.
At last but not the least our great full thanks is also extended to our group
member, for carrying out this project very well.
3
4. TABLE OF CONTENT
Sr no.
1
2
3
4
5
6
7
8
9
Content
Preface
Acknowledge
Introduction
Indian printing industry overview
Vision & mission of the company
About the company
Quality assurance
Product and service
Overall production process
Production process of pouch
Gravure printing
Pouch making
Flexographic Printing
Process overview
Conclusion
Bibliography
Page no.
2
3
5
8
9
11
12
24
25
30
37
38
39
44
45
4
5. INDIAN PRINITING INDUSTRY OVERVIEW
"Print - It‟s everywhere! It‟s on your coffee table; in your freezer; on the bumper of
your car. It can be found on your walls, your doorstep, and on your clothes. It‟s on
your mail, in your wallet, and most often in your hands."
The Indian Printing Industry, growing at a rate of 12% per annum, comprises more
than 250,000 big, small and medium printers. The current annual turnover of the
industry is more than INR 50,000 crores (USD 11 Billion).
The industry has undergone a revolutionary change in the last 15 years. In 1990,
India initiated a process of reforms aimed at shedding protectionism and embracing
liberalization of the economy. Privatization was initiated with the aim of
integrating the Indian economy with the world economy. This change opened the
doors for the Indian Print Industry to modernize, by investing in the latest of
technology and machinery.
In recent years, the printing industry in India has seen record levels of growth,
owing to liberalized regimes, globalization and progress in automation. The
industry has grown leaps and bounds due to the latest technology and machinery,
quality standards and production capacities.
The printing industry in India is slowly progressing from the heavy machinery
using industry to a more software-centric business. The Indian printers are today
equipped with the latest computer controlled printing machines and flow lines for
binding, while state-of-the-art digital technologies are used in pre-press. UV digital
printing and inkjet technology are also on the rise in India. The advent of global
brands, rising consumerism and growth of the pharmaceutical industry have seen
an increase in the scope for package printing. Giving an optimistic outlook of the
industry, the package printing sector is growing at the annual rate of 17 percent,
commercial printing at a rate of 10-12 percent and digital printing at robust 30
percent.
The digital printing industry is seeing significant transformations with new
technologies & applications providing cost-effective and customized solutions. For
the foreseeable future, offset and digital will not only co-exist, but will also
complement each other- with offset taking the medium-to-longer jobs and digital
performing on short-to-medium run lengths.
The booming Indian economy, increasing consumerism, entry of global brands in
the country and opening of the sector to foreign investors are bound to offer
growth opportunities to the industry.
5
6. The industry is dominated by five separate and distinct processes:
1.
2.
3.
4.
5.
Lithography
Letterpress
Flexography
Gravure
Screen printing.
6
8. VISION AND MISSION OF THE
COMPANY
VISION
“AARPEE PACKAGING” is to become the best among the
packaging industry by understanding consumers and consumers‟
expectation better and by continually innovating and improving
their products, services and processes.
MISSION
“AARPEE PACKAGING” mission is to consistently deliver strong
business results and superior returns to by consumers with the best
of their products to healthier and enjoyable lives
8
9. ABOUT THE COMPANY
AARPEE PACKAGING was established in the year 2009. They are one of the
prominent manufacturers, exporters, service provider and suppliers of a vast range
of Packaging Pouch, Printing Services, Printing Solutions, Food Packaging Pouch,
Pouch Bag, Re Winder Machine, Coating Machine, Printing Machine, Aligner
System, Slitting Machine and Cutting Machine. In addition, they provide highly
effective and efficient printing service. Their products and services are highly
demanded and acclaimed in the industry for their high reliability and superior
quality standards. They are able to achieve a position of repute among the clients
by providing them quality approved products at industry leading prices. We
provide these products to the clients as per their specific needs and demands.
Their sophisticated infrastructural facility is equipped with latest technology
based machines and equipment like high-speed dry coating and laminating
machines, automatic slitting machines, high-speed multi-color rotogravure
machines and extrusion poly coating. The facility is segregated into various
departments by the management, in order to ensure smooth execution of each
involved process. Their infrastructural facility namely comprises department like
administration, procurement, manufacturing, quality control, sales and
marketing department and product designing. They do not use any kind of adhesive
of other solvents in our lamination process, which make their products
environment friendly and odorless. The processes related to their printing service
are carried out at their in-house designing unit, which is equipped with
latest graphic designing software. They render these services to the clients as per
their specific demands and estimated budget.
9
10. Year of
Establishment
2009
Legal Status of
Firm
Sole Proprietorship (Individual)
Nature of Business
Supplier, Manufacturer, Exporter,
Service Provider
Number of
Employees
Upto 10 People
Turnover
Rs. 50 Lakh - 1 Crore ( or US$ 100 K 200 K Approx.)
DETAILS
Company name
:
AARPEE PACKAGING
Contact Person
:
Mr. Prithvish Pandya
Mobile / Cell Phone
:
+(91)-9173331240
Telephone
:
+(91)-(79)-55215243
Address
:
B-3, Maruti Industrial Park, Opposite
Naroda Fire Station, Vijay Mill
Compound, Naroda Menco
Road,Ahmedabad - 380015, Gujarat, India
10
11. Quality Assurance
AARPEE PACKAGING holds an advantageous reputation in the pouching and
plastic industry because of their product quality, reliability and durability, safety &
dependability. They as a leading manufacturer are committed to produce and
supply quality products & services right in time every time. They ensure to
improvise their product quality by working together with every individual in the
company & with vendors and by improving their skill through continuous training
and
improvement
in
process.
In their efforts to meet the market expectations, they ensure that the products they
manufacture comply to significant standards of quality. Moreover, their products'
adherence to the international quality & safety standards, makes them noted in the
international marketplace. Guided by a set of quality objectives, they
employ advanced manufacturing processes & techniques to deliver their clients
with the desired machinery that meets their production requirements.
They take immense care while manufacturing products, for that they use optimum
quality raw material procured from trusted vendors. They also have quality control
mechanism where all the products go through stringent quality tests for ensuring
consistency in their quality. They have clients in national as well as international
market who have shown complete faith in them.
Customer Satisfaction
AARPEE PACKAGING is committed to total customer satisfaction in terms of
quality, punctuality and excellent customer services and offering the products at
competitive prices. The company's well-qualified and professionally competent
team of designers are aware of the modern fashion trends and strive to incorporate
them in the development procedures.
11
13. Packaging Pouch
They have a exclusive range of Packaging Pouch. Packaging Pouch, because of
their excellent vapor and moisture barrier properties. Available in different sizes,
shapes and colors, they also offer customized products based on our clients' need
and specifications.
1. Plastic Pouch
Their clients can avail premium quality of plastic product.. Plastic Pouch, which
is available in different sizes as per the demands and needs of the customers.
Their pouches are highly lauded for their unique quality, durability and keeps the
product fresh for long time.
2. Vacuum Pouch
They are offering an high-end quality of vacuum pouch. These pouches are
available in very attractive and catchy designs to cater the need of product
promotion. These are available at variable sizes and shapes.
13
14. 3. Flexible Laminated Pouch
Their organization is offering Flexible laminated Pouch. These products are used
for various types of packaging solution in food, confectionery, stationery and
other household and commercial applications.
14
15. Printing Services
Their organization deal in best quality of printing services. They are offering fine
quality oriented services to our clients which are situated all round the nation. They
offer these Printing Services at very affordable prices.
1- Paper Printing
The organization is offering Paper Printing. They provide Paper Printing in
standard & custom sizes and with bright colors as per the demands of patrons
and utilizing advanced machinery and techniques.
2- Multi Color Rotogravure Printing
They are offering Multi Color Rotogravure Printing. This Multi Color
Rotogravure Printing can be customized as per our precious customer‟s
specifications. These Rotogravure Printing Machines are widely known for its
durability and quality.
15
16. 3- Foil Printing
They can provide a qualitative range of Foil Printing. This Foil Printing is provided
using good quality papers other materials, procured from recognized vendors. This
Foil Printing is highly acclaimed in the market for their salient feature.
4- Flexo Printing
They are offering an high-end quality of Flexo Printing. Their service is well
known for consistency, accuracy, safety and quality. In our work speed and
efficiency has been the main parameters that have enabled us to maintain such
high quality standards.
16
17. 5- BOPP Printing
They have a exclusive range of BOPP Printing. This BOPP Printing is highly
appreciated by their clients for features such as high stretch ability, fine finish,
clarity and durability.
17
18. Printing Solutions
Their clients can avail premier quality of Printing Solutions. They have a panel of
talented personnel, who are dedicated to offer these Printing Solutions as per
client‟s specifications. Owing to high reliability and flawless printing.
1- Polyester Printing
They are providing polyester printing. They offer this Polyester Printing as per
the current fashion trend by using the premium quality threads. To gratify the
demands of our precious patrons, they offer this Polyester Printing in various
lengths and design.
2- Plastic Bag Printing
Their organization deal in best quality of plastic bag printing. These are highly
effective in safeguarding the items kept within. Made from specially treated bio
degradable plastic, these are also competitively priced and are light in weight.
18
19. 3- Shoping Bag Printing
Their clients can avail premium quality of shopping bag printing. Their range of
Shopping Bag Printing is available in diverse sizes, colors, patterns and designs.
Clients can also get these bags custom made as per their design and size
requirements.
19
20. Food Packaging Pouch
They have a exclusive range of food packaging pouch. Offered pouch is acclaimed
by their clients for its resistance against moisture, water and leakage. Owing to
these features, it is widely used for packing from food items.
1- Dry Fruits Pouch
They offer a huge gamut of Dry fruits Pouch. These pouches are widely
demanded in the market owing to their tamper resistance, moisture proof and
durable prints. Perfect for packaging different types of dry fruits.
2- Khajoor Pouch
They are offering Khajoor Pouch. This Packaging Pouch for Khajoor Pouch is
made from high quality of raw material. Which ensure durability at its user end?
These products are available in market at most economical rates.
20
21. 3- Khakhra Pouch
Their organization is offering Khakhra Pouch. The array of Khakhra Pouch can
be availed in multi-colored printings. Further, it can be customized to suit the
exact requirement of the customer.
4- Coffee Pouch
They have an exclusive range of coffee Pouch. These pouches are ensuring to be
at par with international quality of standard and norms.
21
22. Pouch Bag
Their organization deal in best quality of pouch bag. This Pouch Bag is commonly
used in the food for the packaging of spices, ready-to-cook food items, cereals,
grains, condiments, dairy products and even confectionery items.
1- Laminated Pouch
They are offering laminated Pouch. These are available in different colors, styles
and finishes that meet variegated demands of the clients. Available in market
leading price.
2- EVOH Pouch
They are offering an high-end quality of EVOH Pouch. These Pouches are made
out of 3/5/7 layer EVOH based film laminated with Polyester to give you better
strength & shelf life. You can pack your product with flushing of Nitrogen also.
22
23. 3- Aluminum Pouch
They are engaged in offering a wide range of aluminum foil pouch in market.
Add prestige to your product with this innovative bag and it folds flat before
filling. Their experts use high quality material for making these Aluminum
Pouch using latest technology.
4- Metalized Pouch
They are widely appreciated in the market for our ability to offer high quality
Metalized Pouch. This pouch is made from high quality fabric, threads and other
material procured from the trusted vendors of the market.
23
24. OVERALL PRODUCTION PROCESS (PLASTIC)
PRODUCT LAYOUT
RAW MATERIAL
END PRODUCT
PROCESS
GRANULES
TRANSPARENT PLASTIC SHEETS
(PP MACHINE)
TRANSPARENT
PROCESS
PLASTIC SHEETS
(GRAVURE/FLEXO)
PRINTED PLASTIC SHEETS
(FOR POUCHES/BAGS)
FINISHING DONE IN SLITTING
MACHINE
PRINTED
PLASTIC SHEETS
PROCESS
POUCHES
(POUCHING MACHINE)
OVERALL PRODUCTION PROCESS (PAPER)
PRODUCT LAYOUT
RAW MATERIAL
PLAIN PAPER
SHEETS
END PRODUCT
PROCESS
PRINTED PAPER SHEETS
(GRAVURE/FLEXO)
FINISHING DONE IN SLITTING
MACHINE
24
25. PRODUCTION PROCESS OF POUCHES
1.) PRODUCTION OF TRANSPARENT PLASTIC SHEETS:
MACHINERY: Polypropylene Machine
BOUGHT FROM: Konark Machines, Ahmedabad
PURCHASED IN: 2008
RAW MATERIAL: Granules (Polypropylene, Homopolymer)
SUPPLIER: Reliance Polymer
The process of production of plastic pouches starts with manufacturing
transparent plastic sheets from the granules, which are made up of
Polypropylene/Homopolymer. This is a raw material for AARPEE PACKAGING
supplied by RELIANCE POLYMER, Jamnagar. The machine that is used for
production of transparent plastic sheet is PP Machine (Polypropylene Machine).
AARPEE PACKAGING had bought this machinery from KONARK, Ahmedabad.
This machinery is 5-6 years old.
This process is known as BLOWN FILM PROCESS. The detailed process
is described below:
25
26. PP MACHINE
Blown Film
Plastic bags and sacks are made by the Blown Film process – a form of Film
Extrusion. Blown film is created when the molten plastic material (or melt) is
extruded through a ring-shaped die to form a continuous tube of plastic which is
simultaneously inflated with air to form a plastic bubble. The bubble must be
maintained at a constant pressure throughout the production run.
The bubble is carried through variable speed rollers to the point where it reaches
the required size and is cooled by air to convert it into a solid film tube of the
desired thickness or gauge. The tubing is then guided by pinch rolls to become
„Lay Flat‟ film which is wound, slit and trimmed automatically before being
converted into a wide range of film and bag products – often involving printing
and sealing.
26
27. The Process
Plastic melt is extruded through an annular slit die, usually vertically, to form a
thin walled tube. Air is introduced via a hole in the centre of the die to blow up the
tube like a balloon. Mounted on top of the die, a high-speed air ring blows onto the
hot film to cool it. The tube of film then continues upwards, continually cooling,
until it passes through nip rolls where the tube is flattened to create what is known
as a ' lay-flat' tube of film. This lay-flat or collapsed tube is then taken back down
the extrusion ' tower' via more rollers. On higher output lines, the air inside the
bubble is also exchanged. This is known as IBS (Internal Bubble Cooling).
The lay-flat film is then either kept as such or the edges of the lay-flat are slit off to
produce two flat film sheets and wound up onto reels. If kept as lay-flat, the tube of
film is made into bags by sealing across the width of film and cutting or
perforating to make each bag. This is done either in line with the blown film
process
or
at
a
later
stage.
Typically, the expansion ratio between die and blown tube of film would be 1.5 to
4 times the die diameter. The drawdown between the melt wall thickness and the
cooled film thickness occurs in both radial and longitudinal directions and is easily
controlled by changing the volume of air inside the bubble and by altering the haul
off speed. This gives blown film a better balance of properties than traditional cast
or extruded film which is drawn down along the extrusion direction only.
27
28. 3 layer die head with air ring and internal bubble
cooling
Film bubble going into a collapsing
frame
Blown Film Line In Action
Taking an edge trim from film web
28
30. 2.) GRAVURE PRINTING (PRINT ON PAPER AND PLASTIC).
MACHINERY: Gravure
BOUGHT FROM: Precision Gravure Pvt. Ltd.
PURCHASED IN: 2009
Gravure printing is an example of intaglio printing. It uses a depressed or sunken
surface for the image. The image areas consist of honey comb shaped cells or wells
that are etched or engraved into a copper cylinder. The unetched areas of the
cylinder represent the non-image or unprinted areas. The cylinder rotates in a bath
of ink called the ink pan.
As the cylinder turns, the excess ink is wiped off the cylinder by a flexible steel
doctor blade. The ink remaining in the recessed cells forms the image by direct
transfer to the substrate (paper or other material) as it passes between the plate
cylinder and the impression cylinder.
Gravure printing is characteristically used for long run, high quality printing
producing a sharp, fine image. Additionally, the gravure cylinder has a long service
life and will yield a very large number of impressions without degradation.
GRAVURE MACHINE
30
31. GRAVURE CYLINDER
Different gravure cylinders are used for different colours. The gravure
machine at AARPEE Packaging has capacity of using maximum 6 different
colours in an image. One cylinder has a life of 1 and a half year.
The major unit operations in a gravure printing operation are:
o
o
o
o
Image preparation
Cylinder preparation
Printing
Finishing
31
32. Gravure Inks - Solvent Based, Water Based
Gravure inks are fluid inks with a very low viscosity that allows them to be
drawn into the engraved cells in the cylinder then transferred onto the substrate. In
order to dry the ink and drive off the solvents or water, which essentially replaces
most of the solvent, the paper is run through Gas fired or electric fired driers. The
ink will dry before the paper reaches the next printing station on the press. This is
necessary because wet inks cannot be overprinted without smearing and smudging.
Therefore, high volume air dryers are placed after each printing station.
The solvent-laden air from the dryers is passed through either a solvent
recovery system or solvent vapor incinerator. A typical recovery system uses beds
of activated carbon to absorb the solvent. Saturated beds are regenerated by steam.
The solvent laden steam is then condensed and the water and solvent separate by
gravity. Greater than 95 percent of the ink solvents can be recovered using this
process (Buonicore). The solvents can either be reused or destroyed by
incineration.
Water based inks, especially used for packaging and product gravure, require a
higher temperature and longer drier exposure time in order to drive off the water
and lower vapor pressure constituents. As mentioned subsequent sections, Flexo
and Gravure inks are very similar and the constituents are essentially the same.
Again, a pollution control device may be needed.
Gravure Press Design and Equipment
Web-fed gravure presses account for almost all publication, packaging, and
product gravure printing. These presses are generally custom manufactured
machines designed for a specific range of products. The typical press is highly
automated and consists of multiple print units. The printing mechanism in a
rotogravure press consists of a gravure cylinder and a smaller, rubber clad
impression cylinder.
Other types of gravure presses in commercial use today are sheet-fed, intaglio
plate, and offset gravure. These types of presses are used primarily for special
printing applications.
32
34. Diagram showing gravure printing
The gravure cylinders vary in size according to the engraving to be done on them
Diagram showing gravure printing
34
35. Cutting and finishing:
After the printing is done, the printed plastic sheet/paper roll is then moved
to the slitting machine. 100-150 metres of printed plastic/paper roll is produced in
one minute. In the cutting machine the final product is given finishing as shown in
the picture below.
SLITTING MACHINE
35
36. Applications:
Typical gravure printed products include:
o
o
o
o
o
o
o
Food packaging
Wall paper
Wrapping paper
Furniture laminates
Paneling
Greeting cards
Magazines
HANDLING WASTE
The wastage plastic material that comes out of the slitting machine is used in
making plastic niwar (sutra). AARPEE Packaging sells this waste at Rs. 10 per kg
to the local manufacturers of plastic niwar.
36
37. 3.) POUCH MAKING
MACHINERY: Pouching Machine
BOUGHT FROM: Shree Vinayak Packaging Machines, Ahmedabad
Pouch or Bag making is the last step in the entire process. Our machines have
been well equipped with electronic controlled clutch and computer control
system to check the accuracy of each and every single piece.
Our machines can manufacture pouches of various kinds of Center sealed, Side
sealed, Standby packs, Re-Sealable, Gazette etc.
37
39. 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. As with Gravure and
Lithographic printing, the various tones and shading are achieved by overlaying
the 4 basic shades of ink. These are magenta, cyan, yellow and black. Magenta
being the red tones and cyan being the blue.
The flexo printer at AARPEE Packaging has 6 stations and has the capacity
producing 180 metres printed plastic/paper roll in one minute.
of
The major unit operations in a flexographic printing operation are:
o
o
o
o
Image preparation
Platemaking
Printing
Finishing
Below is a process flow diagram for flexographic printing:
Image Preparation
Image preparation begins with camera-ready (mechanical) art/copy or
electronically produced art supplied by the customer. Images are captured for
printing by camera, scanner or computer. Components of the image are manually
assembled and positioned in a printing flat when a camera is used. This process is
called stripping. When art/copy is scanned or digitally captured the image is
assembled by the computer with special software. A simple proof (brown print) is
prepared to check for position and accuracy. When color is involved, a color proof
is submitted to the customer for approval.
Flexographic Plate Making
Flexographic and letterpress plates are made using the same basic technologies
utilizing a relief type plate. Both technologies employ plates with raised images
(relief) and only the raised images come in contact with the substrate during
printing. Flexographic plates are made of a flexible material, such as plastic, rubber
or UV sensitive polymer (photopolymer), so that it can be attached to a roller or
39
40. cylinder for ink application. There are three primary methods of making
flexographic plates; photomechanical, photochemical and laser engraved plates.
40
41. Flexographic Printing Presses
The five types of printing presses used for flexographic printing are the stack type,
central impression cylinder (CIC), in-line, newspaper unit, and dedicated 4-, 5-, or
6-color unit commercial publication flexographic presses. All five types employ a
plate cylinder, a metering cylinder known as the anilox roll that applies ink to the
plate, and an ink pan. Some presses use a third roller as a fountain roller and, in
some cases, a doctor blade for improved ink distribution.
41
42. Flexographic Inks
Flexographic inks are very similar to packaging gravure printing inks in that they
are fast drying and have a low viscosity. The inks are formulated to lie on the
surface of nonabsorbent substrates and solidify when solvents are removed.
Solvents are removed with heat, unless U.V. curable inks are used.
42
43. Finishing
After printing, the substrate may run through a number of operations to be
"finished" and ready for shipment to the customer. Finishing may include
operations such as coating, cutting, folding and binding.
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).
MAIN DIFFERENCE BETWEEN GRAVURE MACHINE
AND FLEXO PRINTING:
1.) In gravure machine, high quality images and be printed containing
text as well as picture. While in flexo printer only text can be printed.
2.) In gravure machine, the 6 stations are arranged in a line horizontally.
While in flexo printer the six stations are arranged vertically. Flexo
printer occupies less space as compared to gravure machine.
43
44. CONCLUSION
It was a great learning experience at the factory of AARPEE PACKAGING. The
opportunity was one which helped in practical understanding of the functional
subjects which are being learnt in our course. Studying AARPEE PACKAGING as a
company who has adopted incredible strategies has really helped in better
understanding of the concepts.
44
45. BIBILIOGRAPHY
(n.d.). Retrieved from o http://www.pafa.org.uAWQSk/processes-26/blown-film
(n.d.). Retrieved from o http://www.bpf.co.uk/Plastipedia/Processes/Blown_Film.aspx
(n.d.). Retrieved from o http://www.bpf.co.uk/plastipedia/processes/default.aspx
(n.d.). Retrieved from o
http://dwb4.unl.edu/Chem/CHEM869E/CHEM869ELinks/qlink.queensu.ca/~6jrt/chem210/Page4.html
(n.d.). Retrieved from o http://www.printfair.in/industry.htm
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