ELECTRONIC ROTOGRAVURE PRINTING CYLINDER

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Gravure printing is a high-speed roll-to-roll printing technique which can overcome the disadvantages of inkjet and reproduce the process flow in Figure 1 with much higher throughput. Gravure is commonly used in the graphic arts industry for medium to long print runs where uniformity and versatility are required. Gravure printed products span a wide range, including bank notes, gift wrap, magazines, and postage stamps.

Gravure is an intaglio printing process, which means that the image carrier has the image etched below the surface of the non-image area. The gravure image carrier is an engraved cylinder patterned with individual wells that form a continuous image when printed. There are five main aspects of the gravure printing press: an engraved cylinder, doctor blade, ink fountain, impression roller, and drying press [GAA]. Figure 2 shows a schematic of a typical gravure printing process.

In gravure printing, the engraved cylinder is submerged in an ink fountain and then rolled over the substrate. A tightly pressed blade, called the doctor blade, wipes off excess ink from the non-image areas of the cylinder surface before contact with the substrate. The gravure cylinder most commonly consists of a steel core covered by a layer of copper, which is then patterned and covered with a thin layer of chrome to protect against wear from the doctor blade. The average lifetime for copper-chrome cylinders is between two to three million impressions, which is equivalent to a week of nonstop printing. Cylinders can be reused by stripping the chrome and copper layers. Modern engraving systems are capable of transferring digital images directly to the cylinder surface, which has helped to reduce the lead time for engravings to a few hours [GAA].

Gravure has a number of advantages over inkjet. First, gravure has a higher throughput because of its wider print area and its faster printing speed of up to 2000 ft/min. Gravure is also capable of simultaneously depositing multiple drops in a parallel fashion, as opposed to inkjet which must deposit drops one at a time in a serial fashion. Second, gravure can sustain long print runs because the cells are continuously refilled with ink as the roll is rotated into the ink fountain, and the roll is not subject to clogging. Finally, gravure is a very versatile process capable of printing on a broad range of substrates with a wide range of ink viscosities. These advantages also help gravure compete against other high-speed printing processes such as flexography, letterpress, lithography, and screen printing. Gravure is a mechanically simple process with fewer controlling variables than other printing processes, which tends to give it a more consistent image quality.

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Description

INTRODUCTION
FIGURE. SCHEMATIC OF GRAVURE PRINTING PROCESS [YIN]
PROPERTIES
B.I.S. SPECIFICATION
CONSTRUCTION OF GRAVURE PRINTING SYSTEM
FIGURE. MODEL OF LABORATORY GRAVURE PRINTER [SOURCE:
ALEJANDRO DE LA FUENTE]
FIGURE. SCHEMATIC OF PRINTING PROCESS FOR LABORATORY
GRAVURE PRINTER [SOURCE: ALEJANDRO DE LA FUENTE]
FIGURE. BLUEPRINT OF GRAVURE CYLINDER [SOURCE: ALEJANDRO
DE LA FUENTE]
PROCESS AND COMPONENTS OF ROTOGRAVURE PRINTING
ENGRAVED CYLINDER
PROCESS
FEATURES OF ROTOGRAVURE PRINTING
ADVANTAGE AND DISADVANTAGE OF ROTOGRAVURE PRINTING
ADVANTAGES
OTHER APPRECIATED FEATURES INCLUDE:
DISADVANTAGES
SHORTCOMINGS OF THE GRAVURE PRINTING PROCESS INCLUDE:
MARKET OVERVIEW OF ROTOGRAVURE PRINTING MACHINE
TECHNIQUE OF CYLINDER MAKING
FIGURE. TOP VIEW OF A COPPER/CHROME CYLINDER AND PROCESS
FLOW FOR REUSING CYLINDERS [GAA]
FIGURE. CLOSE-UP OF CHROME CRACKS IN POLISHED CYLINDER
FIGURE. CELL SIZES AND SCREEN ANGLES FOR ELECTROMECHANICAL ENGRAVING [GAA]
FIGURE. PROCESS FLOW FOR CHEMICALLY ETCHING CYLINDERS
[SOURCE: ALEJANDRO DE LA FUENTE]
FIGURE. COMPARISON OF MICROLAB ROLL TO INDUSTRIAL ROLL
FIGURE. COMPARISON OF CHEMICAL ETCHING WITH INDIRECT LASER
METHOD OF MANUFACTURING ROTOGRAVURE CYLINDERS WITH
ALUMINUM BASE
CYLINDER MANUFACTURING FACILITIES
IN-HOUSE BASE SHELL MANUFACTURING
PLATING LINE
HIGH PRECISION COPPER POLISHING LINE
ENGRAVING
CYLINDER PROOFING
QUALITY CHECKS
QC AT EACH AND EVERY STAGE OF THE PROCESS:-
EMBOSSING
WELDING (ROLL INNER TUBE WELDING)
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY

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)

Additional information

Plant Capacity

80 Cylinder/Day

Land & Building

(1000 sq.mt.)

Plant & Machinery

US$ 100000

Rate of Return

37%

Break Even Point

50%