Industrial training on Polyfilms

Dashmesh foils
&
Sadhana Laminators
&
Innovative Gravure
 Manufacturing process of poly-film
This plastic film manufacturing process starts with melting down
small plastic pellets, ( called resin ), until they become molten and
pliable. The molten plastic is pushed, ( extruded ), through a circular
die to form a continuous tube of plastic called the bubble.
 Process of making Sachet Roll
• Film roll (Raw material)
• Printing on rotograver machine.
• Lamination process
• Curing process
• Slitting process
• Packing
 Printing (Rotogravure)
• A image is etched onto the surface of a metal cylinder.
• The etched area is filled with ink.
• The cylinder is rotated, printing onto the paper.
 Application
• High quality art and photo books
• Postage stamps and postcards
• Packaging
• Expensive magazines (glossy covers)
 Advantages
• Consistent colour
• High speed
• Good results on cheap paper
• Very durable printing plate
• Ink dries on evaporation - paper can pass through multiple
machines for colour prints with CMYK

Disadvantage
• High costs of printing plates and cylinders
• Only good for long print runs
 Cylinder manufacturing process
• Raw material - MS cylinder
• Surface grinding on lathe
• Nickel plating (8-10 microns)
• Copper plating (300-400 microns)
• Surface grinding (smoothening cylinder
surface)
• Hardness testing ( Req. hardness:-
195HRC – 210HRC)
• Engraving process
• Chrome plating (7-8 microns)
• Proofing (sample preparation)
 Sachet film costing
Sachet combination :- Pet + aluminum foil + poly (LD)
Pet - 1.4 g/cubic cm ( density)
Aluminum - 2.71 g/cubic cm ( density)
Poly (LD) - 0.92 g/cubic cm ( density)

GSM ( Gram per square meter) - density x thickness of film

Material Density Rate Thickness weight percentage Cost
(g/cubic cm) Rs. / kg micron (gsm)

Pet 1.4 102 12 16.80 21.21 21.63

Aluminim foil 2.71 295 6.5 17.62 22.24 65.60
Poly (LD) 0.92 98 40 36.80 46.46 45.53
Adhesive 300 6.00 7.57 22.72
Ink 900 2.00 2.52 22.72
Total Raw material 79.215 178.20
Packing 4.00
Conversion 40.00

Sachet roll prices / kg 222.20

Thanks