How Gravure coating can eliminate „MUDA“ · PDF fileHow Gravure coating can eliminate „MUDA“ waste Fabian Umbach 6.4 / 7722. Paper 6.4 Fabian Umbach 2 What is MUDA ... Tie

How Gravure coating can eliminate „MUDA“ waste

Fabian Umbach6.4 / 7722

Paper 6.4 Fabian Umbach 2

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.


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


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


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


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


Gravure Engraved Patterns


CHECKING NIP IMPRESSIONS = FOOTPRINT

STEEL ROLL

LOAD

RUBBERCOVEREDROLL

FOOTPRINT


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


FLEX-PACK COATERS

DirectGravure

ReverseGravure

OffsetGravure

SmoothRoll


Smooth Roll CoaterGravure Coater


Gravure Coater with “PGH”Pressurized Gravure Head


DIRECT GRAVURE

BACKING; LINESPEEDUndercut Required

BACKING/GRAVURE = 8-12mm NIP

GRAVURE; 90% to 110% LINESPEED

SOMETIMES REQUIRES POST SMOOTHING


REVERSE GRAVURE

BACKING; LINESPEEDUndercut required


GRAVURE; 50% to 150% OF LINESPEED


OFFSET GRAVURE

BACKING; LINESPEED

BACKING/OFFSET =8-12mm NIP

OFFSET; 95% to 105% OF LINESPEEDUndercut Required

OFFSET/GRAVURE = 8-12mm NIP



SMOOTH ROLL

BACKING; LINESPEEDNO Undercut Required

BACKING/PICKUP = VARY NIP

PICKUP;20% to 150% LINESPEED


PRESSURIZED REVERSE GARVURE

BACKING; LINESPEEDUndercut required

NO AIR ENTRAPMENT AT HIGH SPEED




Series 4000

Cartridge Coating Station


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


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


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


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


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


Thank you

Documents

How Gravure coating can eliminate „MUDA“ · PDF fileHow Gravure coating can eliminate „MUDA“ waste Fabian Umbach 6.4 / 7722. Paper 6.4 Fabian Umbach 2 What is MUDA ... Tie