Products Production Stages and Machinery

Products Production
Stages and Machinery

Content
• Production Stage……………………………………………..……………………pages 3-12
• Products Production Stages……………………………………………………pages 13-32
o Cups and Bowls …………………………………………………………….…pages 14-20
o Bags …………………………………………………………………………….…pages 21-22
o Folding Carton …………………………………………………………….….pages 23-24
o Erected Carton …………………………………………………………….….pages 25-26
o FAFA Products ……………………………………………….…………….…pages 27-32
o RAJA Products ……………………………………………….……………….pages 33-46
• Machinery ..…………………………………………………………………..…..…pages 47-77
• Job Order Production Duration…..…………………………………..…..…pages 78-96
SM For Technical Support – Human Resources Department 2

Production Stages

Slitting
The process of slicing a large roll of paper or other material into narrower strips
What is slitting used for?
• Slitting is a common practice in the

converting industry and is used to
produce material substrates for a
variety of different markets including
packaging, food and beverage,
pharmaceuticals, fashion, and more.
• Slitting is the process most commonly

used in cutting paper, vinyl, thin
plastics, nonwovens, foil, and other
soft, pliable materials.

Sheeting
The process to form something into sheets, such as paper or cloth
What is sheeting used for?
• Sheeting is the process of cutting paper

or other similar materials into specific
lengths and widths.
• Sheeters can take large rolls and create
smaller sheets of material for any
needs.
• Some machines can only do length and
width cuts separately. While others can
do both simultaneously.

Printing
Offset printing Flexo printing
• Is only done on flat surfaces • Can be used on almost any substrate with a
• Widely used printing technique in which flexible surface.
• Incorporates high-definition printing on polybags
the inked image on a printing plate is
or roll stock for stunning colors and graphic
printed on a rubber cylinder and then
clarity.
transferred (i.e., offset) to paper or other • Widely used is due to the advancements in the
material. process, which has led to this high definition, low
cost, flexible printed packaging.

Die Cutting and Punching
Die Cutting Punching
• Is a popular manufacturing technique within • Can be used on almost any substrate with a
the packaging industry. flexible surface.
• Involves the use of a die that is used to cut soft • Incorporates high-definition printing on polybags
materials into a variety of packaging designs or roll stock for stunning colors and graphic
and shapes. clarity.
• Ability to mass-produce custom packaging is • Widely used is due to the advancements in the
where the real value of the die-cutting process process, which has lead to this high definition,
lies. low cost, flexible printed packaging.

Erecting
• Shapes carton blanks, skillets or trays into a rectangular form.
• Closing the pre-cut tabs and slots so that the carton is ready for filling.

Forming
Shaping Cups/Bowl/Bucket into the final cylinder shape

Window patching
• Appling a thin plastic film to a die-cut window on any box or packaging.
• Allows customers to see the product without opening the package.
• Often used to showcase a high-end product.

Folding & Gluing
• The process involves folding carton made of paperboard that is printed, laminated, cut, then
folded and glued.
• The machinery is to fold the carton into its final shape as a container for a product.

Lamination and UV Coating
Lamination is for full coverage of a folding Ultraviolet or UV coating can be used as a
carton. spot coating treatment to provide an eye-
Requires an additional step in the process to catching element to specific areas.
apply the film to the paperboard

Products Production Stages

Noor Products
Cups & Bowls Production
Slitting
Punching
Printing
Flexo
Forming
Sheeting
Die-Cutting
Printing
OffSet
Cups & Bowls

Noor Products
Cups & Bowls Production
CUP & BOWL Molds

Based on the available mold sizes:
Number
Machine Size of UPS
1. Flexo printing option can be 3.5 Oz 6
used with punching machines. 5 Oz 5
10 Oz 5
9 Oz inner mold 6
2. Offset printing is used if molds are 9 Oz outer mold 6
Punching 12 Oz inner mold 6
unavailable, then proceeding with die machines 12 Oz outer mold 6
cutting. 16 Oz inner mold 5
16 Oz outer mold 5
Hummus Bowl 3
16 Oz short and wide
S/W 4

Noor Products
Stages Cups and Bowl
Slitting Paper Slitter
Sheeting Reel sheeter
Printing HEIDELBERG 102 / Rapida 5 or 6 depending on the required colors
Die Cutting or
BOBST EXPERTCUT 106 /BOBST SA SP102SE / PUNCHING CC1400
Punching
Forming DEBAO 600S
Cup | 9 Oz Cup | 12 Oz Cup | 12 Oz Cup | 16 Oz Cup | 16 Oz
Double Wall Single Wall Double Wall Single Wall Double Wall
Final Product

Noor Products
Stages Cups and Bowls
Offset
HEIDELBERG 102 /Rapida 5 or 6 depending on the required colors
Printing
Die Cutting BOBST EXPERTCUT 106
PUNCHING
Punching Not Needed
CC1400
DEBAO 16 OZ / DEBAO 4 OZ,
Forming DEBAO 7 OZ DEBAO 10, 12 OZ DEBAO 5 OZ DEBAO 16 OZ S/W DEBAO 130 OZ DEBAO 170 OZ
DEBAO 9 OZ FUSION
Cup | 9 Oz Cup | 16 Oz Cup | 16 Oz Bucket | 130 Bucket | 170
Cup | 4 Oz Cup | 7 Oz | A Cup | 7 Oz | B Cup | 10 Oz | A Cup | 5 Oz
Single Wall Short & Wide Tall Pint Oz Oz
Final Product

Noor Products
Offset
HEIDELBERG 102 / Rapida 5 or 6 depending on the required colors
Printing
PUNCHING
Punching Not Needed Not Needed
CC1400
SEE MACHINERY
DEBAO 4 OZ, 21 , 26, 32, 48 OZ
SEE MACHINERY RUIDA 24, 32 SEE MACHINERY 20, SEE MACHINERY SEE MACHINERY
Forming DEBAO 44 OZ NEW TOP 2 OZ FUSION / NEW RUIDA 24, 32 OZ / SEE
20, 22 OZ OZ 22 OZ 20, 22 OZ 21 , 26, 32, 48 OZ
TOP 3.5 OZ MACHINERY 21
OZ
Bowl | 44 Oz Cup | 2 Oz Cup | 3.5 Oz Cup | 32 Oz | A Cup | 22 Oz Cup | 24 Oz Cup | 20 Oz | A Cup | 20 Oz | B Bowl | 21 Oz | A Bowl | 31 Oz
Final Product

Noor Products
Offset
Printing
Die Cutting BOBST EXPERTCUT 106 / BOBST SP102
PUNCHING
Punching Not Needed Not Needed
CC1400
RUIDA 32 ,38, 56, RUIDA 32 ,38, 56, 85
SEE MACHINERY 85 OZ / SEE MACHINERY SEE MACHINERY SEE MACHINERY RUIDA 15, 108 OZ / SEE MACHINERY 21 RUIDA 64, 130
Forming RUIDA 36 OZ
21 , 26, 32, 48 OZ SEE MACHINERY 21 , 26, 32, 48 OZ 21 , 26, 32, 48 OZ 21 , 26, 32, 48 OZ OZ SEE MACHINERY 21 , , 26, 32, 48 OZ OZ
21 , 26, 32, 48 OZ 26, 32, 48 OZ
Bowl | 26 Oz | B Bowl | 32 Oz | B Bowl | 48 Oz Bowl | 26 Oz | A Bowl | 21 Oz | B Bowl | 15 Oz Bowl | 32 Oz | C Bowl | 46 Oz Bucket | 64 Oz Bowl | 36 Oz | B
Final Product

Noor Products
Offse
Printing
BOBST EXPERTCUT 106 /
Die
BOBST EXPERTCUT 106 / BOBST SP102 BOBST SP102 / UV BOBST EXPERTCUT 106 / BOBST SP102
Cutting
COATER - I (If needed)
Forming RUIDA 32 ,38, 56, 85 OZ RUIDA 36 OZ RUIDA 32 ,38, 56, 85 OZ RUIDA 32 ,38, 56, 85 OZ RUIDA 6, 8 OZ DEBAO 10, 12 OZ
Cup | 10 Oz Short &
Bucket | 85 Oz Bowl | 36 Oz | A Bowl | 38 Oz Bowl | 56 Oz Cup | 6 Oz Cup | 8 Oz
Wide | B
Final
Product

Noor Products
Bags Production
Window Patching
Slitting Flexo Printing
(if needed)
Forming
Forming Forming Handle SOS
Satchel & SOS Window
Satchel

Products Production Stages
Stages Paper Bag
Printing CI Flexo printing
Window Patching Window Patching Not Needed
Forming SATCHEL INLINE (SOMTAS BAG MASTER S) SOS - SMALL (ZD-FJ08C) HANDLE BAG FORMING (CURIONI)
Satchel with Window Satchel SOS SOS with Handle
Final Product

Noor Products
Folding Carton
Slitting Sheeting Offset Printing Die Cutting
Window Patching
Folding Carton Gluing Folding
(if needed)

Noor Products
Stages Folding Carton
Slitting Slitting if needed
Sheeting Sheeting machine
Printing HEIDELBERG 102/ Rapida 5 or 6 depending on the required colors
Folding BOBST EXPERTFOLD 110/Omega
Window Patching Not Needed Window Patching
Gluing OMEGA FOLDER GLUER 110/145
Side Seam Boxes Crash-Lock Bottom Boxes 4 Corner Boxes 6 Corner Boxes
Final Product

Noor Products
Erected Carton
Sheeting Offset Printing Die Cutting
Window Patching
Erected Carton Gluing
(if needed)

Noor Products
Stages Erected Carton
Sheeting Sheeter
Offset Printing HEIDELBERG 102 / Rapida 5 or 6 depending on the required colors / UV COATER if needed
Die Cutting BOBST EXPERTCUT 106/ BOBST SA SP102SE
Window Patching Window patching Not Needed
Gluing ERECTOR L1000 2L (II) / ERECTOR L1560 4L (I) / ERECTOR L1560 4L (II)
Clamshell with Window Clamshell Tray Fry Box
Final Product

FAFA Products
Lamination
Flexo Printing (If needed) Slitting
Sandwich wrap, laminates, thermal paper

& sugar wrap Sheet Cutting (if needed)

FAFA Products
Stages FAFA - PRODUCTS
Flexo Printing Cronoflex C.I / KBA C.I
Lamination Nordmeccanica Lamination 1 / Nordmeccanica Lamination 2 Not Needed
Slitting Not Needed Schaivi Slitter / HCI 1000 Limu Slitter Casjier Schaivi Slitter
Sheet Cutting Hollweg Sheeter Not Needed
Burger Wrap Laminates Laminates Thermal - Printed Thermal - UnPrinted Sugar Wrap
Final Product

FAFA Products
Flexo Printing Lamination Slitting
(If needed)
Mono Layer Confectionery Wrap Bread Wrap Adhesive Label Water Label Poly
sleeves

FAFA Products
Stages FAFA - PRODUCTS

Flexo Printing Cronoflex C.I / KBA C.I Aqua Flex Cronoflex C.I / KBA C.I
Nordmeccanica
Lamination Not Needed
Lamination 1-2
Slitting Schaivi Slitter HCI 1000 HCI 1000 HCI1300 / Vensak Slitter HCI 1000 / Vensak Slitter Not Needed
Mono Layer Confectionery Wrap Bread Wrap Adhesive Label Water Label Poly Sleeves
Final Product

FAFA Products
Thermal Sticker
Flexo Printing Lamination Slitting
(If needed)
Blister Foil
Medical Pouch
Flexo Printing Slitting Lids Punching
Foil Lids

FAFA Products
Stages FAFA - PRODUCTS Stages FAFA - PRODUCTS Stages FAFA - PRODUCTS

Flexo Printing Aqua Flex / Cronoflex C.I Flexo Printing Cronoflex C.I Flexo Printing Cronoflex C.I / KBA C.I /
Lamination Nordmeccanica 1-2 Not Needed Lamination Nordmeccanica Slitting HCI1300
HCI 1000 / HCI1300 / Slitting HCI 1000 / HCI1300 Lids Punching Bulldog lids foil
Slitting Schaivi Slitter
Not Needed
Medical Pouch Foil Lids
Thermal Sticker Blister Foil
Final Product Final Product

Final Product

RAJA Products
Book and Magazine
Offset Printing Folding Manual Gathering
OR
Final Product Trimming Glue Binding Stitch Binding
Manual
Gluing

RAJA Products
Book and Magazine
Satges RAJA Products

Offset Printing Speed Master CD102
Folding Komori MBOFolding
Gathering ManualGathering
Glue Binding or Stitch Binding Sulby PerfectBinder (Glue) or Sewing Stitch
Trimming Polar Guillotine
Final Product

RAJA Products
Daily Promotion
Offset Printing Folding Stitch Binding Final Product
Flyers
Offset Printing Trimming Folding Final Product

RAJA Products
Daily Promotion Flyers
Stages RAJA Products Stages RAJA Products
Offset Printing Speed Master CD102 Offset Printing Speed Master CD102
Folding Komori MBO Folding
Stitch Binding Saddle Stitch
Folding Komori MBO Folding
Final Product
Final Product

RAJA Products
Diary Final
Offset Printing Folding Stitch Binding Trimming Glue Binding Product
Calendar
Final
Offset Printing Trimming Product

RAJA Products
Diary Calendars
Offset Printing Speed Master CD102 Offset Printing Speed Master CD102
Folding Komori MBOFolding Trimming Polar Guillotine
Stitch Binding Sewing Stitch
Glue Binding Sulby PerfectBinder
Final Product
Final Product

RAJA Products
Wall Calendar
Final
Offset Printing Trimming Product
Spiral and Tent Spiral Calendar

Final
Offset Printing Trimming Stitch Binding Glue Binding Product

RAJA Products
Wall Calendar Spiral and Tent Spiral
Calendar

Trimming Polar Guillotine Stitch
Double Drill
Binding
Glue Binding Sulby Perfect Binder
Fina l Product
Fi na l Product

RAJA Products
NCR
Collecting/
Offset Printing Perforating
Numbering
Final
Trimming Stitch
Product

RAJA Products
NCR
Stages RAJA Products
Offset Printing Rotatek RK 250/200
Collecting/
BAMA Collator
Numbering
Perfora ting Perforation
Stitch Stitch
Tri mmi ng Polar Guillotine
Fi na l Product

RAJA Products
NCR Booklets and Pads
Collecting/ Stitch
Offset Printing Perforating
Numbering
Trimming
Pad Booklet

RAJA Products
NCR Booklet NCR Pad
Stages RAJA Products
Offset Printing Rotatek RK 250/200 Stages RAJA Products
Collecting/
Numbering
BAMA Collator Printing Rotatek RK 250
Perforating Perforation Collecting/ BAMA
Stitch Wire Stitch
Trimming Polar Guillotine Numbering Collator

RAJA Products
Letter Head
Offset Printing Glue Binding Trimming Final Product
Business Card
Offset Printing Trimming Final Product

RAJA Products
Letter Head Business Card

Satges RAJA Products Satges RAJA Products
Printing GTO V/IV Printing GTO V/IV
Glue Binding Sulby Perfect Binder Trimming Polar Guillotine

Machines

NOOR OFFSET Printing
Machine Name Plate Size Paper Min size Paper Max size Blanket Size Paper Thickness Speed Unit Power
Rapida - 5 Color 795 x 1060 mm 480 X 340 mm 1060 X 740 mm 860 x 1070 mm 0.04 - 1.2 mm 18000 Sheet/h 265 Kw
Rapida - 6 Color 795 x 1060 mm 480 X 340 mm 1060 X 740 mm 860 x 1070 mm 0.04 - 1.2 mm 18000 Sheet/h 280 Kw

NOOR OFFSET Printing
Machine Name Plate Size Paper Min size Paper Max size Blanket Size Paper Thickness Speed Unit Power
Heidelberg CD 102 790 x 1030 mm 340 X 480 mm 1020 X 720 mm 840 x 1052 mm 0.03 - 1 mm 15000 Sheet/h 250 Kw

RAJA OFFSET Printing
Machine name HEIDELBERG GTO 2 color
No. of printing units 2 Default Makeready time 1
No. of coating units 0 Makeready time per color 0.5 0.5
Paper gripper margin 1 Plate Cost (Single Plate)
Plate Set Back Minimum production speed 1500
Stock thickness GSM Min 50 Max 400 Average production speed 4500
Minimum sheet size 18 10 Maximum production speed 5000
Maximum sheet size 50 35 Press make ready wastage 0.03 0.05
Plate size 52 37 Press running wastage 0.02
Machine name HEIDELBERG GTO 1 color
No. of printing units 1 Default Makeready time 0.5
Stock thickness Min GSM50 Max GSM400 Average production speed 2500
Machine name ROTATEK - 200
Plate Set Back Minimum production speed 3000 Meter Per Hour
Stock thickness Min GSM 50 Max GSM 200 Average production speed 6000 Meter Per Hour
Minimum Roll size * 21.6 Maximum production speed 6500 Meter Per Hour
Maximum Roll size* 48.4 Press make ready wastage 0.05 0.05
Machine name HEIDELBERG 4 color
Stock thickness Min GSM 50 Max GSM 400 Average production speed 4500
Machine name HEIDELBERG 74 2 col

Stock thickness Min GSM 50 Max GSM 400 Average production speed 9000
Plate size 74.5 60.5 Press running wastage 0.02
FAFA OFFSET Printing
Material size Printing Repeat Speed according to material

Machine Name Power Speed Unit
Max Reel Width Min reel width Min Max Paper NCR Sticker Thermal x Roll to roll Roll to sheet
Rotatek 250 500 mm 18 Kw 250 Meter/min 22 inch 24 inch 150 150 x x 250 200

FAFA FLEXO Printing

Max Reel Width Min reel width Min OPP PET PE Sticker Blister Paper 55 gsm Al. foil
K&B 1450 mm 500 mm 222 Kw 500 Meter/min 395 mm 300 400 - 450 350 x 150 x 150 - 200

FAFA FLEXO Printing

Max Reel Width Min reel width Min Max OPP PET PE Sticker Blister Paper 55 gsm Al. foil
Markandy 830 250 mm 1.9 Kw 90 Meter/min 212.7 mm 381 mm x x x 50 x x 45

FAFA FLEXO Printing

Max Reel Width Min reel width Min Max OPP PET PE Sticker Blister Paper 55 gsm Al. foil
Aqua Flex 500 mm 90 mm 55 Kw 150 Meter/min 298.45 mm 615.975 mm x x x 50 - 70 50 - 75 75 x

NOOR FLEXO Printing
Machine Name Repeat length Reel width Sleeve width Roll Dia. Thickness Mechanical Operation Unit Power
Flexo CI 360 - 800 670 - 1570 mm 600 - 1500 mm 800 - 1000 25 - 360 gsm 300 150-250 Meter/min 350 Kw
Burger Wrapping
Reel Size Speed according to material

Machine Name Speed Unit Power
Max Min Cutting Length Paper Paper
Hollweg Sheeter 1525 mm 200 - 750 mm 300 cut/Min 4 Kw 300 300

Bag Making
Machine Name Bag Length Bag Width Gusset depth Folding buttom Paper Thickness Speed Unit Power
Smotas 1 100 - 400 mm 55 -300 mm 10. - 80. x 25 - 100 gsm 600 Bag/min 40 Kw
Smotas 2 150 - 670 mm 80 - 350 mm 12. - 80. 20 - 30 25 - 100 gsm 600 Bag/min 20 Kw

Bag Making
SOS 1 270 - 530 mm 110 - 280 mm x 60 - 150 50 - 150 gsm 240 Bag/min 18.5 Kw
SOS 2 190 - 370 mm 80 - 200 mm x 50 - 100 45 - 130 gsm 260 Bag/min 13.5 Kw

Bag Making
Handel bag 1 380 - 770 mm 220 - 540 mm x 80 - 210 90 - 170 gsm 120 Bag/min 39 Kw
Handel bag 2 320 - 650 mm 220 - 540 mm x 80 - 200 80 - 130 gsm 110 Bag/min 35 Kw

Bag Making
Paper Handle (Twisted) 150 M/min 1.1 Kw

Rope making only
Paper Handle (Flat) 150 M/min 2.2 Kw

Bag Making
Offline handel pasting 230 - 320 mm 200 - 270 mm x x X 25 30 Bag/min 3 Kw

Die Cutting
Materials thickness
Machine Paper Min size Paper Max size Speed Power
Paper Solid board corrugated
Expertcut 106 400 X 350 mm 1060 X 760 mm From 70 gsm 1000 gsm 4 mm 9000 sheet/h 45 Kw

Lamination and Uv
Machine Min size Max size Thickness Speed Power
Auto Flute Laminator Asp Ire 450 x 450 mm 1450 x 1450 mm 120 - 800 gsm 150 M/min 19 Kw
High Speed Spot Varnish Uv 300 x 300 mm 1080 x 1480 mm 80 - 500 gsm 6000 Sheet/min 63 Kw

Lamination
Material size Speed according to material

Machine Name Power Speed Unit x x
Max Reel Width Min reel width PET PE OPP/OPP Al.foil/PET
Super simplex 1300 - 1400 - 1500 mm 28 Kw 450 Meter/min x x 300 200 400 150

Cups
Product sizes in mm Speed Pcs/min

Machine Thickness
Cup TOD BOD Height Mechanical Operation
DEBAO 600S Double & single wall 70 - 95 40 - 75 50 - 135 65 - 90 60 230 - 400 gsm

Cups

Machine Thickness
DEBAO 5000A bucket 170 oz. 150 - 225 110 - 170 130 - 220 30 - 50 23 230 - 400 gsm

Cups

Machine Thickness
SEE SCM600 32 oz. popcorn 48 - 122 35 - 95 40 - 135 70 - 80 56 230 - 400 gsm
SEE SCM300 hummus bowl 110 - 168 105 - 129 50 - 120 70 - 80 56 230 - 400 gsm
mcdo bowl 110 - 168 105 - 129 50 - 120 70 - 80 56 230 - 400 gsm
SEE SCM300 26 oz. 110 - 168 105 - 129 50 - 120 70 - 80 56 230 - 400 gsm
Sultan Burger - Bowl 110 - 168 105 - 129 50 - 120 70 - 80 56 230 - 400 gsm

Folder Gluers
Machine Max Blank width Min Blank width Max Blank length Min Blank length Thickness Speed Power
Bobst Expert fold 1100 mm 126 mm 800 mm 60 mm Max 800 gsm 450 M/min 29 Kw
Omega Allpro 145 1450 mm 240 mm 1350 mm 100 mm Max 800 gsm 400 M/min 33 Kw

Erector
Machine Blank Length Blank Width Height of flap Height of flap + LID Thickness Speed Unit Power
Erector Mc-2 Lan 100 - 450 mm 100 - 420 mm 15 - 250 mm 50 - 250 mm 200 - 600 gsm 360 Pec/min 8 Kw
Erector Mc-4 Lan 100 - 450 mm 100 - 300 mm 15 - 220 mm 50 - 220 mm 200 - 600 gsm 800 Pec/min 11 Kw

Window Patching
Machine Blank Length Blank Width Window length Window width Thickness Speed Pcs/h According to blank length Power
Length 1 Lane 2 Lane 3 Lane

265 mm 40,000 80,000 120,000
Window Patching 100 - 1180 mm 80 - 670 mm 55 - 720 mm 30 - 514 mm 250 - 800 gsm 40 Kw
365 mm 36,000 72,000 108,000
570 mm 24,000 48,000 72,000

Cutter
Machine Cutting width Cutting depth Smallest cut Knife thickness Speed Power
Guillotine Cutter 1550 mm 1930 mm 30 - 90 mm 12 mm 400 mm/sec 8 Kw

Cutter
Machine Max. Forming area Stroke Max Depth Reel Width Thickness Speed Water Power
Lid 1 410 x 300 mm 40 - 300 mm 50 mm 430 mm Max 500 mic 8 - 32 C/min 0.3 mᶟ/h 14 Kw
Lid 4 520 x 320 mm x 80 mm 560 mm 0.1 - 1.5 mm 10 - 35 c/min 0.3 mᶟ/h 21 Kw
Lid 5 780 x 570 mm x Max 100 400 - 810 mm Max 1.8 mm 55 C/min x 245 Kw

Paper LID forming
Machine Paper cover Dia. Raw material Thichness Speed Power
PAPER LID FORMING 1 130 - 190 mm PE coated paper 300 - 480 mic 30 - 40 PCS/min 8 Kw
PAPER LID FORMING 2 65 125 mm PE coated paper 280 - 450 mic Max 50 PCS/min 6.5 Kw
PAPER LID FORMING 3 125 - 190 mm PE coated paper 0.3 - 0.6 mm 120 PCS/min 4 Kw

Punching
Machine Reel Dia. Reel width Reel Thichness Punching area Tolerance Speed Power
Punch machine ≤1500 ≤1400 ≤400 1380 x 520 mm ±0.25 ≤350 15 Kw

Sheeter
Machine Reel Width Reel Dia Cut off range Pile Height Pile weight Chuck Reel weight Speed Power
400 - 1600 mm 300 - 2100 mm 460 - 1778 mm Max 1650 mm 2500 Kg 76 - 305 mm 3200 Kg 300 M/min 55 Kw

Job Order Production Duration
SM For Technical Support – Human Resources

Department 78
Production Processes
Production stages in producing a current JO “as required”
• Printing
• Lamination
• Slitting
• Die cutting
• Gluing
• Forming
o Bags
o Cups

Job Orders
Production stages in producing a There are 2 sources of JO:
current JO “as required”
• Printing
1- JO from FINSYS
• Lamination
• In which we can calculate
• Slitting duration manually
• Die cutting
• Gluing
2- JO from INSOFT
• Forming
• Can be calculated manually
o Bags
• Or it’s given at the end of the JO
o Cups

FINSYS Job Order
Data To Consider:
• Qty “1”
• No. color “2”
• No. of ups “2”
• No. of sheets or meters “3”
• Process of the Jo “4”
• Machine will be used “4”

Job Order Duration Calculation
Printing Machine:
1. Make Ready Time:

o 30 Minutes Fixed Machine Time
o 15 Minutes per Process color “CMYK” and 20 Minutes
per Spot Color “Pantone”
2. Running Time:
o First, we need the number of sheets or meters: Shape 3
or calculated as
( Order quantity in pcs / No. of ups ) = No. of sheets
o No. of sheets / Avg. machine speed = Running time
Add both hours together to get all the printing process needed time

Printing Machines And Its Avg. speed
Machine Name Location Printing Type Avg. Speed UOM
First 2000 Sheet - 6500
KBA I or II NCPI Offset Sheet/H
From 2001 Sheet - 13500
CD 102 - 103 NCPI Offset 9500 Sheet/H
GTO 2 AL Raja Offset 4500 Sheet/H
HEIDELBERG 74 AL Raja Offset 4500 - 9000 for 2 colors Sheet/H

SATCHEL INLINE (SOMTAS BAG
NCPI Flexo 19500 Meter/Min
MASTER S)
KYMC NCPI Flexo 9000 Meter/Min
CI I or II FAFA Flexo 250 for I & 350 for II Meter/Min
Mark Andy FAFA Flexo 75 Meter/Min
Aqua Flex FAFA Flexo 50 Meter/Min
Rotatek RK250 FAFA Flexo 75 Meter/Min
Rotatek RK200 AL Raja Offset 6000 Meter/Min

Lamination Machine:
1. Make Ready Time:
o 3 Hours Fixed Machine Time
2. Running Time:
o No. of sheets or meters / Avg. machine speed =
Running time
Slitting Machine:
1. Make Ready Time:
2. Running Time:
o No. of meters / Avg. machine speed = Running time

Lamination Machines Avg. speed
Machine Name Location Type Avg. Speed UOM
Nordmeccanica Combi 120 layer 1 – 150 layer

FAFA lamination/wax Meter/Min
wax 2&3
Swafam 1050 AL Raja Thermal Lamination 1200 Sheet/Min
Cold lamination AL Raja Cold lamination 500 Sheet/Min
Aspire NCPI Glue Lamination 3000 Sheet/Min

Slitting Machines Avg. speed

Schiavi Slitter FAFA Slitter 150 Meter/Min
HCI 1000 or 1300 Slitter FAFA Slitter 150 Meter/Min
Lemu Slitter FAFA Slitter 130 Meter/Min
Vensak Slitter FAFA Slitter 100 Meter/Min
Nicely Slitter NCPI board slitting 200 Meter/Min

Poly Sleeve FAFA Sleeve Making 3000 Meter/min
Weijeen Sheeter FAFA Sheeting 7500 Pcs/Min
Hollweg Sheeter FAFA Sheeting 50000 Pcs/Min

Die-cutting Machine:
1. Make Ready Time:
o 3-4 Hours Fixed Machine Time
2. Running Time:
o No. of sheets or meters / Avg. machine
speed = Running time
Gluing Machine:
1. Make Ready Time:
2. Running Time:
o No. of sheets or meters / Avg. machine
speed = Running time

Die Cutting Machines Avg. speed
Machine Name Location Avg. Speed UOM
BOBST SA SP102SE NCPI 4500 Sheet/H
BOBST EXPERTCUT 106 PER NCPI 6750 Sheet/H
BOBST EXPERTCUT 106 LER I NCPI 6750 Sheet/H
BOBST EXPERTCUT 106 LER II NCPI 6750 Sheet/H
Manual Die Cutting - 1 or 2 NCPI 800 Sheet/H
Flexo Diecutting TCY-NB NCPI 6750 Sheet/H

DAYUAN CC1400 (Flexo
NCPI 2 hour make ready - 13500 Punch/H
Punching)
HEIDELBERG LETTER PRESS AL Raja 3000 Sheet/H
AUTO DIE CUTTING & AUTO
AL Raja 1200 Sheet/H
FOIL STAMP TL-780
DIE CUTING MACHINE TYMK
AL Raja 500 Sheet/H
1040 / MANUAL

Gluing Machines Avg. speed
Machine Name Location Avg. Speed
By meter per hour depending on box

BOBST EXPERTFOLD 110 NCPI
style

OMEGA FOLDER GLUER 110 NCPI
style

OMEGA FOLDER GLUER 145 NCPI
style
No make ready time - 11250

Flex Folder Gluer TCY-N5 NCPI
Sheet/H

Bags forming:
1. Make Ready Time:
o 6 Hours Fixed Machine Time for handle bag
2. Running Time:
o No. bags/ Avg. machine productivity = Running time
Cups & Bowls forming:

1. Make Ready Time:
2. Running Time:
o No. of Cups / Avg. machine productivity = Running time

Bags Forming Machines Avg. speed
SATCHEL INLINE (SOMTAS BAG MASTER S) NCPI 20000 Pcs per Hour
SATCHEL BAG FORMING (SOMTAS BAG
NCPI 20000 Pcs per Hour
MASTER L)
SOS – MEDIUM (ZD-FJ11C) NCPI 7200 Pcs per Hour
SOS – SMALL (ZD-FJ08C) NCPI 8400 Pcs per Hour
HB SOS – LARGE (ZD-QFJ21) NCPI depends on paper grade (recycled or virgin)
HANDLE BAG FORMING (CURIONI) NCPI depends on paper grade (recycled or virgin)
HANDLE PASTING_OFFLINE NCPI 960 Pcs per Hour
HANDLE BAG CI KYMC NCPI 13500 Mtr per Hour
Paper handle twisted ZD - YS 300 NCPI 6000 Pcs per Hour
Paper handle flat ZY - FJ 200 NCPI 6000 Pcs per Hour
Weijeen Poly Bag FAFA 1 hour make ready - 3000 Pcs/Min

Cups Forming Machines Avg. speed
DEBAO 9 oz NCPI 65 Pcs per Min
DEBAO 4 oz, Fusion NCPI 65 Pcs per Min
CP006 DEBAO WT NCPI 65 Pcs per Min
DEBAO 10, 12 oz NCPI 55 Pcs per Min
NEW TOP 2 oz NCPI 90 Pcs per Min
NEW TOP 3.5 oz NCPI 90 Pcs per Min
RUIDA 6, 8 oz NCPI 20 Pcs per Min
DEBAO 16 oz S/W NCPI 55 Pcs per Min

Cups Forming Machines Avg. speed
SEE MACHINERY 20, 22 oz NCPI 55 Pcs per Min
SEE MACHINERY 21 oz NCPI 55 Pcs per Min

SEE MACHINERY 21, 26, 32, 48
NCPI 55 Pcs per Min
oz
RUIDA 36 oz NCPI 18 Pcs per Min
RUIDA 32 ,38, 56, 85 oz NCPI 18 Pcs per Min
BL013 RUIDA JWZ 160 NCPI 18 Pcs per Min

Lids Forming Machines Avg. speed
Per minute. Output depends on

BLOW MOLDING - DP 420S I NCPI 12
number of cavity by each size.

BLOW MOLDING - DP 420S II NCPI 12

BLOW MOLDING - DP 420S III NCPI 12

BLOW MOLDING - PPBG-520 D - 4 NCPI 19
Paper lid (ZGJ-60) NCPI 25 Pcs per Min
Paper lid (ZGJ-60) 64oz NCPI 25 Pcs per Min

INSOFT Job Order
Data To Consider:
• Qty “1”
• No. color “2”
• No. of sheets
or meters “3”
• No. of ups “4”
With the same previous

criteria

INSOFT Job Order
Or we can just summation
the total no. of hours
beside each process with
its machine type from
INSOFT job order
In which:
o Operation Name: The
process needed
o Work Center: The
Machine Name
o R. Time: Running Time
o M. Time: Make Ready
Time

Thank You

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What is slitting used for?

• Slitting is a common practice in the

• Slitting is the process most commonly

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What is sheeting used for?

• Sheeting is the process of cutting paper

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Cups & Bowls

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CUP & BOWL Molds

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Sandwich wrap, laminates, thermal paper

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Stages FAFA - PRODUCTS

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Flexo Printing Slitting Lids Punching

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Stages FAFA - PRODUCTS Stages FAFA - PRODUCTS Stages FAFA - PRODUCTS

Final Product Final Product

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Final Product Trimming Glue Binding Stitch Binding

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Satges RAJA Products

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Spiral and Tent Spiral Calendar

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Offset Printing Speed Master CD102

Glue Binding Sulby Perfect Binder

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Final Product Final Product

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