How Gravure coating can eliminate MUDA waste Fabian Umbach 6.4 / - - PowerPoint PPT Presentation

How Gravure coating can eliminate „MUDA“ waste

Fabian Umbach 6.4 / 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 flexibility
• 2. Waiting long setup
• 3. Unnecessary transport
• 4. Over processing or incorrect processing Right equipment ?
• 5. Excess inventory log setup low flexibility
• 6. Unnecessary movement
• 7. Defects Right equipment ?
• 8. Unused employee creativity continues improvement

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Cost of the product

Production cost w/o labor

Raw Material Energy Machine efficiency Material waste Market and process related Process related Process and operator related

Process and operator related

Process investment

Initial Investment for new equipment Process related

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Example of interactions

Material waste Energy Process is not ideal

Initial Investment for new equipment

Machine 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 RUBBER COVERED ROLL FOOTPRINT

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COATER/DRYER set-up

Coater

Smooth roll

Backing Roll not Undercut

Pan Fed

Direct Gravure

Backing Roll Undercut Sleeve Pan Fed Enclosed Applicator Pressurized Gravure Head

Dryer

Air Floatation Nozzles Roll Support

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FLEX-PACK COATERS

Direct Gravure Reverse Gravure Offset Gravure Smooth Roll

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Smooth Roll Coater

Gravure Coater

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Gravure Coater with “PGH” Pressurized Gravure Head

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DIRECT GRAVURE

BACKING; LINESPEED Undercut Required BACKING/GRAVURE = 8-12mm NIP GRAVURE; 90% to 110% LINESPEED SOMETIMES REQUIRES POST SMOOTHING

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REVERSE GRAVURE

BACKING; LINESPEED Undercut 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 LINESPEED Undercut Required OFFSET/GRAVURE = 8-12mm NIP GRAVURE; 10% to 25% OF LINESPEED

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SMOOTH ROLL

BACKING; LINESPEED NO Undercut Required BACKING/PICKUP = VARY NIP PICKUP;20% to 150% LINESPEED

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PRESSURIZED REVERSE GARVURE

BACKING; LINESPEED Undercut 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 Products

Product

• 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 Components

Substrates

• 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 Structures

PET 12.6µ (PRINT) FOIL 6.3µ Tie layer 6µ LDPE 25 µ PRIMER 0.04µ

Retort Package

PET 12.6µ (PRINT) FOIL 6.3µ ADHESIVE 3.25 – 5.5µ LDPE 25 µ PRIMER 0.04µ

Retort Package

E X L C L C L C

Material Cost for EX Tie layer 5 Euro/kg vs. Adhesive 3Euro/kg Less coat weight in LC process. Investment difference 1 compl. extruder; laminator ….. vs. Coater Dryer station High flexibility with coating station primer and adhesive coating No process problems with Tie layer

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Typical Product Structures

LDPE 12.6µ Board FOIL 6.3µ Tie layer 6µ LDPE (Heat Seal) 25µ LDPE 12.6µ Tie layer 6µ LDPE 12.6µ Board FOIL 6.3µ PRIMER 0.04µ LDPE (Heat Seal) 25µ LDPE 12.6µ PRIMER 0.04µ E X L C E X L C

Beverage Package Beverage Package Material Cost for EX Tie layer vs. Primer and less coat weight Investment High 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

Overproduction Excess Inventory

• LC can reduce Tie layer problems

Defects

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Thank you