Detailed Project Report on FLEXOGRAPHIC PRINTING LABELS (CAPACITY: 4000 METERS/DAY)

The formulation of UV flexo inks with low viscosity, high color strength, high cure speeds and adhesion is a considerable challenge for ink formulators. The rheology of UV flexoinks is significantly improved with measured combinations of resins, additives and pigment wetting vehicles. Oligomers are the primary resins in an energy-cured ink and provide basic ink properties, while monomers are used primarily for viscosity reduction. Relative to optimizing anchorage of these oligomer-monomer carriers to the substrate, surface modification by corona, flame or atmospheric plasma all have potential to do so because of their efficient surface roughening and functionalizing effects. This collaborative study was undertaken to understand the potential synergistic interactions between different atmospheric pressure surface modification techniques and different oligomer types in UV flexo ink formulations, and the overall impact of these synergies on ink adhesion to various unprimed, flexible polymer-based surfaces.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org


FLEXOGRAPHIC PRINTING LABELS
(CAPACITY: 4000 METERS/DAY)
[EIRI/EDPR/4714] J.C.: 2934XL


The formulation of UV flexo inks with low viscosity, high color strength, high cure
speeds and adhesion is a considerable challenge for ink formulators. The rheology
of UV flexoinks is significantly improved with measured combinations of resins,
additives and pigment wetting vehicles. Oligomers are the primary resins in an
energy-cured ink and provide basic ink properties, while monomers are used
primarily for viscosity reduction. Relative to optimizing anchorage of these
oligomer-monomer carriers to the substrate, surface modification by corona, flame
or atmospheric plasma all have potential to do so because of their efficient surface
roughening and functionalizing effects. This collaborative study was undertaken to
understand the potential synergistic interactions between different atmospheric
pressure surface modification techniques and different oligomer types in UV flexo
ink formulations, and the overall impact of these synergies on ink adhesion to
various unprimed, flexible polymer-based surfaces.

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CONTENTS

INTRODUCTION

HISTORY OF FLEXOGRAPHIC PRINTING

CLEAR PACKAGING

TYPES OF PRINTING PROCESSES

OFFSET LITHOGRAPHY

ROTOGRAVURE PRINTING

FLEXOGRAPHIC PRINTING

TYPES OF PRINTING INKS

TYPES OF FLEXOGRAPHIC INKS

CHOICE OF SUBSTRATE IS ALSO ONE OF THE MAIN FACTORS IN INK
SELECTION

SUBSTRATES CAN INCLUDE:

4 COMMON TYPES OF FLEXOGRAPHIC INKS

HERE ARE SOME MORE DETAILS ON THESE TYPES OF INKS, AND WHAT
APPLICATIONS THEY'RE BEST FOR:

1. WATER BASED

2. SOLVENT BASED

3. ULTRAVIOLET (UV) AND ELECTRON BEAM (EB)

4. OIL BASED

FLEXOGRAPHIC INKS ARE SEPARATED INTO TWO CLASSIFICATIONS:
VOLATILE AND ENERGY CURABLE

THE UNCOATED FILMS USED FOR UV BASED INK-

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FLEXOGRAPHIC INK FOR POLYETHYLENE FILM

UV INK

HOW FLEXO PRINTING WORKS

THE STEPS FOR PREPARING PHOTOPOLYMER PLATES ARE

INKS

SUBSTRATES

FLEXOGRAPHIC INK DELIVERY SYSTEM

PRESS CONFIGURATIONS

COMMON IMPRESSION CYLINDER (CIC) PRESS

STACK PRESS

CORRUGATED PRESS

REPEAT LENGTH

PLATE TYPES

MOLDED RUBBER

PHOTOPOLYMER

LASER ABLATED PLATES

PLATE ELONGATION

DISTORTION

TYPE WEIGHT

DOT GAIN IN FLEXOGRAPHY

PLATE DUROMETER

INKS

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WATER-BASE INK

SUBSTRATES

CHEMISTRY OF UV (PHOTOINDUCED) CURING TECHNOLOGY

THE MAIN COMPONENTS OF SUCH FORMULATI ONS BASED ON RADICAL
POLYMERIZATIONS ARE:

PROPAGATION

TERMINATION

USES AND APPLICATION

MARKET CATEGORIES

CORRUGATED

FLEXIBLE PACKAGING

GIFT WRAP AND WALLPAPER

FOLDING CARTONS

RIGID PAPER BOXES

ENVELOPES

PAPER GROCERY BAGS

PLASTIC CARRIER BAGS

MILK CARTONS

TAGS AND LABELS

PRE-PRINTED LINERBOARD

APPLICATION AREAS OF UV CURING INKS

PROPERTIES OF MACHINE

ADAVANTAGE & DISADVANTAGE

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ADVANTAGE:-

BENEFIT: HIGHLY AUTOMATED

BENEFIT: COST EFFICIENT

BENEFIT: FAST

DISADVANTAGE:-

DRAWBACK: NOT IDEAL FOR SMALLER JOBS

DRAWBACK: SETUP CAN BE TIME CONSUMING

MARKET POSITION

KEY PLAYERS

FLEXOGRAPHIC PRINTING INKS MARKET, BY APPLICATION

FLEXOGRAPHIC PRINTING INKS MARKET, BY REGION

COMPETITIVE MARKET SHARE

MACHINERY SUPPLIERS

RAW MATERIAL SUPPLIERS

INK

SUBSTRATE

MACHINERY PHOTOGRAPHS

RAW MATERIAL PHOTOGRAPHS

PRODUCT PHOTOGRAPHS

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 40,000 Mtrs/Day

Land & Building (7000 sq.ft.) Existing

Plant & Machinery Rs. 2.26 Cr

Working Capital for 1 Month Rs. 21.05 Lac

Total Capital Investment Rs. 2.52 Cr

Rate of Return 89%

Break Even Point 40%