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

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. Paper 6.4 Fabian Umbach 2

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 Paper 6.4 Fabian Umbach 3

Cost of the product Production cost w/o labor Raw Material Market and process related Energy Process related Machine efficiency Process and operator related Process and operator related Material waste Process investment Initial Investment for new Process related equipment Paper 6.4 Fabian Umbach 4

Example of interactions Material waste Energy Process is not Initial Investment for new Machine efficiency ideal equipment Production cost w/o labor goes up and you will lose profit Paper 6.4 Fabian Umbach 5

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 Paper 6.4 Fabian Umbach 6

Gravure Engraved Patterns Paper 6.4 Fabian Umbach 7

CHECKING NIP IMPRESSIONS = FOOTPRINT RUBBER COVERED ROLL FOOTPRINT LOAD STEEL ROLL Paper 6.4 Fabian Umbach 8

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 Paper 6.4 Fabian Umbach 9

FLEX-PACK COATERS Offset Smooth Direct Reverse Gravure Roll Gravure Gravure Paper 6.4 Fabian Umbach 10

Smooth Roll Coater Gravure Coater Paper 6.4 Fabian Umbach 11

Gravure Coater with “PGH” Pressurized Gravure Head Paper 6.4 Fabian Umbach 12

DIRECT GRAVURE BACKING; LINESPEED Undercut Required BACKING/GRAVURE = 8-12mm NIP GRAVURE; 90% to 110% LINESPEED SOMETIMES REQUIRES POST SMOOTHING Paper 6.4 Fabian Umbach 13

REVERSE GRAVURE BACKING; LINESPEED Undercut required BACKING/GRAVURE = 8-12mm NIP GRAVURE; 50% to 150% OF LINESPEED Paper 6.4 Fabian Umbach 14

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 Paper 6.4 Fabian Umbach 15

SMOOTH ROLL BACKING; LINESPEED NO Undercut Required BACKING/PICKUP = VARY NIP PICKUP;20% to 150% LINESPEED Paper 6.4 Fabian Umbach 16

PRESSURIZED REVERSE GARVURE BACKING; LINESPEED Undercut required NO AIR ENTRAPMENT AT HIGH SPEED BACKING/GRAVURE = 8-12mm NIP GRAVURE; 50% to 150% OF LINESPEED Paper 6.4 Fabian Umbach 17

Series 4000 Cartridge Coating Station Paper 6.4 Fabian Umbach 18

Typical Products Product Package Type Interm. Product • Processed Meat • Pouches, Vacuum • Primer Coated Film • Processed Cheese Packages • Top Coated Film • Fresh Red Meat • Pouches, Wraps • Silicon Film • Bulk Liquids • Barrier, Shrink Bags • Adhesive coated Film • Cereal/Cake Mix • Pouches, Bag in Box • Medical Devices Films • Inner Liners • Coffee • Pouches, Thermal Formed • Fresh Produce • Brick Packs, Pouches • Snacks • Breathable Bags • Bags Paper 6.4 Fabian Umbach 19

Flex-Pack Components Coatings Substrates • Primers 0.04-0.4 gsm • PET 1-10 µ • Adhesives 3.25-6.5 gsm • PE 1-8 µ • PVDC 1.6-6.5 gsm • Al foil 20-60 µ • Wash-coats 0.8-1.5 gsm • BOPP/OPP 0.4-2 µ • PVOH 0.5 gsm • CPP 1-4 µ • Lacquer 5.0 gsm • Nylon 0.4-2 µ • Acrylic Polyurethane 0.3 gsm • METPET 1-10 µ • Varnish 0.02 – 0.04 gsm • Cellophane 0.8-1 µ Paper 6.4 Fabian Umbach 20

Typical Product Structures PET 12.6µ PET 12.6µ (PRINT) (PRINT) E L X Tie layer 6µ ADHESIVE 3.25 – 5.5µ C FOIL 6.3µ FOIL 6.3µ L L PRIMER 0.04µ PRIMER 0.04µ C C LDPE 25 µ LDPE 25 µ Retort Package Retort Package 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 Paper 6.4 Fabian Umbach 21

Typical Product Structures LDPE 12.6µ LDPE 12.6µ Board Board E LDPE 12.6µ LDPE 12.6µ L X Tie layer 6µ C PRIMER 0.04µ FOIL 6.3µ FOIL 6.3µ E L X Tie layer 6µ PRIMER 0.04µ C LDPE (Heat Seal) 25µ LDPE (Heat Seal) 25µ 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 Paper 6.4 Fabian Umbach 22

Conclusions Which MUDA � Over Processing • LC can reduce material cost � Over Processing • LC can reduce initial investment � Overproduction • LC can increase flexibility � Excess Inventory � Defects • LC can reduce Tie layer problems Paper 6.4 Fabian Umbach 23

24 Thank you Paper 6.4 Fabian Umbach