REPORT ON PRODUCTION MANAGEMENT

SUBMITTED BY:-

KASTRUI BAPAT (1304)DRASHTI BHATT (1306)ANSHUL JANGRA (1317)SUNITA MOTWANI (1333)VIJAY NIKAM (1335)FELIX PERIERA (1342)DRASHTI SHERDIWALA (1352)

SUBMITTED TO:-PROF. GURMEET SINGH SIKHNRIBM

12/31/2013

PREFACEThe 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.

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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.

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TABLE OF CONTENT

Sr no. Content Page no.

1 Preface 22 Acknowledge 33 Introduction

Indian printing industry overview 5

Vision & mission of the company 8

About the company 94 Quality assurance 11

5 Product and service 126 Overall production process 24

Production process of pouch 25

Gravure printing 30

Pouch making 37

Flexographic Printing 38

7 Process overview 398 Conclusion 449 Bibliography 45

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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.

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The industry is dominated by five separate and distinct processes:

1. Lithography2. Letterpress3. Flexography4. Gravure5. Screen printing.

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AARPEE PACKAGING

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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

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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.

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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

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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 SatisfactionAARPEE 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.

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Packaging Pouch

Printing Services

Printing Solutions

Food Packaging Pouch

PRODUCT AND SERVICES

Pouch Bag

Packaging PouchThey 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.

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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.

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Printing ServicesTheir 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.

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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.

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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.

 

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Printing SolutionsTheir 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.

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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.

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Food Packaging PouchThey 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.

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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.

 

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Pouch BagTheir 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.

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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.

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OVERALL PRODUCTION PROCESS (PLASTIC)

PRODUCT LAYOUT

RAW MATERIAL END PRODUCT

OVERALL PRODUCTION PROCESS (PAPER)

PRODUCT LAYOUT

RAW MATERIAL END PRODUCT

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GRANULESPROCESS

(PP MACHINE)TRANSPARENT PLASTIC SHEETS

PROCESS

(GRAVURE/FLEXO)

TRANSPARENT

PLASTIC SHEETS

PRINTED PLASTIC SHEETS

(FOR POUCHES/BAGS)

PRINTED

PLASTIC SHEETS

PROCESS

(POUCHING MACHINE)

POUCHES

FINISHING DONE IN SLITTING MACHINE

PROCESS

(GRAVURE/FLEXO)

PLAIN PAPER SHEETS

PRINTED PAPER SHEETS

FINISHING DONE IN SLITTING MACHINE

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:

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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.

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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.  

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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

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TRANSPARENT PLASTIC SHEETS

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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

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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 Image preparationo Cylinder preparationo Printingo Finishing

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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.

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Diagram showing gravure printing

The gravure cylinders vary in size according to the engraving to be done on them

Diagram showing gravure printing

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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

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Applications:

Typical gravure printed products include:

o Food packagingo Wall papero Wrapping papero Furniture laminateso Paneling o Greeting cardso 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.

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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.

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4.) Flexographic Printing

MACHINERY USED: Flexo Printer

BOUGHT FROM: Gehlot Works, Jodhpur, Rajasthan

PURCHASED IN: 2013

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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 of producing 180 metres printed plastic/paper roll in one minute.

The major unit operations in a flexographic printing operation are:

o Image preparationo Platemakingo Printingo 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

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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 cylinder for ink application. There are three primary methods of making flexographic plates; photomechanical, photochemical and laser engraved plates.

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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. 

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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. 

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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.

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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.

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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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