How Gravure coating can eliminate „MUDA“ · PDF fileHow Gravure coating can...
Transcript of How Gravure coating can eliminate „MUDA“ · PDF fileHow Gravure coating can...
How Gravure coating can eliminate „MUDA“ waste
Fabian Umbach6.4 / 7722
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What is MUDA • Muda is the Japanese word for waste.
• Wastes are costs / activities which are not increasing the value of the product
• WHY ?????
• Customers are not paying for the additional work.
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What is MUDA $$$$ • 8 Waste categories:
1. Overproduction long setup low flexibility2. Waiting long setup 3. Unnecessary transport 4. Over processing or incorrect processing Right equipment ?5. Excess inventory log setup low flexibility6. Unnecessary movement7. Defects Right equipment ?8. Unused employee creativity continues improvement
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Cost of the productProduction cost w/o labor
Raw Material
Energy
Machine efficiency
Material waste
Market and process related
Process related
Process and operator relatedProcess and operator related
Process investmentInitial Investment for new equipment
Process related
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Example of interactions
Material waste Energy
Process is not ideal
Initial Investment for new equipmentMachine efficiency
Production cost w/o labor goes up and you will lose profit
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What is Gravure / Smooth Roll Coating • Gravure or smooth roll coating applies the coating
liquid with a roll to the substrate.
• In case of Gravure coating you have a chrome or ceramic roll which is mechanically or laser engraved cells. With the size of the cells the coat weight is determined. It can be varied by using a Pressurized Gravure Head “PGH” for higher speeds and ctw.
• In case of smooth roll coating the liquid get transferred from a open pan with a smooth chrome roll and gets applied to the web by contact with the
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Gravure Engraved Patterns
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CHECKING NIP IMPRESSIONS = FOOTPRINT
STEEL ROLL
LOAD
RUBBERCOVEREDROLL
FOOTPRINT
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COATER/DRYER set-upCoater
Smooth roll Backing Roll not Undercut
Pan Fed
Direct GravureBacking Roll Undercut
SleevePan FedEnclosed ApplicatorPressurized Gravure Head
DryerAir Floatation NozzlesRoll Support
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FLEX-PACK COATERS
DirectGravure
ReverseGravure
OffsetGravure
SmoothRoll
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Smooth Roll CoaterGravure Coater
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Gravure Coater with “PGH”Pressurized Gravure Head
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DIRECT GRAVURE
BACKING; LINESPEEDUndercut Required
BACKING/GRAVURE = 8-12mm NIP
GRAVURE; 90% to 110% LINESPEED
SOMETIMES REQUIRES POST SMOOTHING
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REVERSE GRAVURE
BACKING; LINESPEEDUndercut required
BACKING/GRAVURE = 8-12mm NIP
GRAVURE; 50% to 150% OF LINESPEED
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OFFSET GRAVURE
BACKING; LINESPEED
BACKING/OFFSET =8-12mm NIP
OFFSET; 95% to 105% OF LINESPEEDUndercut Required
OFFSET/GRAVURE = 8-12mm NIP
GRAVURE; 10% to 25% OF LINESPEED
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SMOOTH ROLL
BACKING; LINESPEEDNO Undercut Required
BACKING/PICKUP = VARY NIP
PICKUP;20% to 150% LINESPEED
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PRESSURIZED REVERSE GARVURE
BACKING; LINESPEEDUndercut required
NO AIR ENTRAPMENT AT HIGH SPEED
BACKING/GRAVURE = 8-12mm NIP
GRAVURE; 50% to 150% OF LINESPEED
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Series 4000
Cartridge Coating Station
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Typical ProductsProduct• Processed Meat• Processed Cheese• Fresh Red Meat• Bulk Liquids• Cereal/Cake Mix• Medical Devices Films• Coffee• Fresh Produce• Snacks
Package Type• Pouches, Vacuum
Packages• Pouches, Wraps• Barrier, Shrink Bags• Pouches, Bag in Box• Inner Liners• Pouches, Thermal Formed• Brick Packs, Pouches• Breathable Bags• Bags
Interm. Product• Primer Coated Film• Top Coated Film• Silicon Film• Adhesive coated Film
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Flex-Pack ComponentsSubstrates• PET 1-10 µ• PE 1-8 µ• Al foil 20-60 µ• BOPP/OPP 0.4-2 µ• CPP 1-4 µ• Nylon 0.4-2 µ• METPET 1-10 µ• Cellophane 0.8-1 µ
Coatings• Primers 0.04-0.4 gsm• Adhesives 3.25-6.5 gsm• PVDC 1.6-6.5 gsm• Wash-coats 0.8-1.5 gsm• PVOH 0.5 gsm• Lacquer 5.0 gsm• Acrylic Polyurethane 0.3 gsm• Varnish 0.02 – 0.04 gsm
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Typical Product StructuresPET 12.6µ(PRINT)
FOIL 6.3µTie layer 6µ
LDPE 25 µPRIMER 0.04µ
Retort Package
PET 12.6µ(PRINT)
FOIL 6.3µADHESIVE 3.25 – 5.5µ
LDPE 25 µPRIMER 0.04µ
Retort Package
EX L
C
LC L
C
Material Cost for EX Tie layer 5 Euro/kg vs. Adhesive 3Euro/kgLess coat weight in LC process.Investment difference 1 compl. extruder; laminator ….. vs. Coater Dryer stationHigh flexibility with coating station primer and adhesive coating No process problems with Tie layer
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Typical Product StructuresLDPE 12.6µBoard
FOIL 6.3µTie layer 6µ
LDPE (Heat Seal) 25µ
LDPE 12.6µ
Tie layer 6µ
LDPE 12.6µBoard
FOIL 6.3µPRIMER 0.04µ
LDPE (Heat Seal) 25µ
LDPE 12.6µ
PRIMER 0.04µ
EX L
C
EX L
C
Beverage Package Beverage Package
Material Cost for EX Tie layer vs. Primer and less coat weight InvestmentHigh Flexibility with coating station primer and adhesive coating No process problems with Tie layer
Less heat problems due to lower extrusion weight higher speeds
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Conclusions Which MUDA
• LC can reduce material cost Over Processing
• LC can reduce initial investment Over Processing
• LC can increase flexibility OverproductionExcess Inventory
• LC can reduce Tie layer problems Defects
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Thank you