Detailed Project Report (DPR) on flexo printing manufacturing facility

FLEXO PRINTING MANUFACTURING FACILITY
[CODE NO.3901]  


Flexible packaging refers to any package or part of a package the shape of which can be readily changed.  Flexible packaging includes, but is not limited to, bags, pouches, liners, and wraps utilizing paper, plastic, film, aluminum foil, metalized or coated paper or film, or  any combination of these materials.   Flexible package manufacturers are sometimes referred to as "converters."  The word "converted" in this use is an industry-specific term that refers to the fact that flexible packaging materials start out as rolls of paper or foil, or beads of plastic resin, and are "converted" into a package or roll of packaging material.
Flexography is a roll-feed web printing process. Flexographic printing is commonly used to print high volumes of labels and packaging. Presses can print on a variety of films, foils, papers, corrugated board, and paperboard and achieve speeds of 500 to 2000 feet per minute.
 

In the simplest and most common form, the flexo process consists of below mentioned components 1) Fountain pan / tray , 2) Fountain roll, 3) Doctor blade , 4) ink-metering ( anilox ) roll , 5) plate cylinder and impression cylinder, 6) Impression roll , 7) Substrate These are illustrated in the figure below. 4/17/2018 13 In the simplest and most common form, the flexo process consists of below mentioned components 1) Fountain pan / tray , 2) Fountain roll, 3) Doctor blade , 4) ink-metering ( anilox ) roll , 5) plate cylinder and impression cylinder, 6) Impression roll , 7) Substrate.
Products printed on flexo presses include adhesive and shrink-sleeve labels (bottle wraps); ice cream cartons; folding cartons; shopping bags; plastic bags; pouches; packets; gift wrap; tissue; envelopes; wallpaper; and disposable plates and cups.
Printing on flexible packaging is almost entirely conducted by rotogravure and wide- web flexographic printing.  The ratio of rotogravure printing to flexographic printing among converters is approximately 1:4.  Flexible packaging printers are likely to be included under SIC codes 2671, 2673, 2674, and 3497.  Typical NAICS codes for this industry include 322221, 326112, 322223, 326111, 322224, 322225, and 332999.  Flexible package printers could also be classified under other SIC and NAICS codes as well depending on other processes conducted at the facility.
Printing, coating, and laminating may all be performed on or in-line with a flexible package printing press and these activities are included in the source category.  One portion of the flexible packaging industry provides fully printed packaging materials (designated "preformed specialty bags") to contract packagers.  Another portion provides combination or laminated materials (designated converted wrap) for printing and/or final packing by captive packaging operations.  Applying coatings is a major capability of flexible packaging converters, so the same facilities may be used to manufacture non-packaging materials such as gift wraps and hot stamp foils.   The industry makes a distinction between labels and wrappers, which are package components, from a product that becomes the entire package and should be called a flexible package. Any printing of shrink-wrap labels or wrappers conducted on or in-line with a flexible package printing press is also considered to be included under the flexible packaging source category.   Printing of self-adhesive labels would not be considered flexible packaging.


COST ESTIMATION


Plant Capacity                    500000 Pcs /day      
Land & Building (600 sq.mt.)    US# 92400         
Plant & Machinery               US# 585000    
Working Capital for 2 Months     US# 1001208
Total Capital Investment        US$ 1748308
Rate of Return                    64%                   
Break Even Point             26%            



INTRODUCTION    
HISTORY OF FLEXOGRAPHIC PRINTING    
CLEAR PACKAGING    
TYPES OF PRINTING PROCESSES    
OFFSET LITHOGRAPHY    
ROTOGRAVURE PRINTING    
FLEXOGRAPHIC PRINTING    
TYPES OF PRINTING INKS    
TYPES OF FLEXOGRAPHIC INKS    
CHOICE OF SUBSTRATE IS ALSO ONE OF THE MAIN FACTORS IN INK SELECTION.    
SUBSTRATES CAN INCLUDE:    
4 COMMON TYPES OF FLEXOGRAPHIC INKS    
HERE ARE SOME MORE DETAILS ON THESE TYPES OF INKS, AND WHAT APPLICATIONS THEY'RE BEST FOR:    
1. WATER BASED    
2. SOLVENT BASED    
3. ULTRAVIOLET (UV) AND ELECTRON BEAM (EB)    
4. OIL BASED    2
FLEXOGRAPHIC INKS ARE SEPARATED INTO TWO CLASSIFICATIONS: VOLATILE
    AND ENERGY CURABLE.    
THE UNCOATED FILMS USED FOR UV BASED INK-    
FLEXOGRAPHIC INK FOR POLYETHYLENE FILM    
UV INK    
HOW FLEXO PRINTING WORKS    
THE STEPS FOR PREPARING PHOTOPOLYMER PLATES ARE    
INKS    
SUBSTRATES    
FLEXOGRAPHIC INK DELIVERY SYSTEM    
PRESS CONFIGURATIONS    
COMMON IMPRESSION CYLINDER (CIC) PRESS    
STACK PRESS    
CORRUGATED PRESS    
REPEAT LENGTH    
PLATE TYPES    
MOLDED RUBBER    
PHOTOPOLYMER    
LASER ABLATED PLATES    
PLATE ELONGATION    
DISTORTION    
TYPE WEIGHT    
DOT GAIN IN FLEXOGRAPHY    
PLATE DUROMETER    
INKS    
WATER-BASE INK    
SUBSTRATES    
CHEMISTRY OF UV (PHOTOINDUCED) CURING TECHNOLOGY    
THE MAIN COMPONENTS OF SUCH FORMULATIONS BASED ON RADICAL
    POLYMERIZATIONS ARE:    
PROPAGATION    
TERMINATION    
USES AND APPLICATION    
MARKET CATEGORIES    
CORRUGATED    
FLEXIBLE PACKAGING    
GIFT WRAP AND WALLPAPER    
FOLDING CARTONS    
RIGID PAPER BOXES    
ENVELOPES    
PAPER GROCERY BAGS    
PLASTIC CARRIER BAGS    
MILK CARTONS    
TAGS AND LABELS    
PRE-PRINTED LINERBOARD    
APPLICATION AREAS OF UV CURING INKS    
PROPERTIES OF MACHINE    
ADAVANTAGE & DISADVANTAGE    
ADVANTAGE:-    
BENEFIT: HIGHLY AUTOMATED    
BENEFIT: COST EFFICIENT    
BENEFIT: FAST    
DISADVANTAGE:-    
DRAWBACK: NOT IDEAL FOR SMALLER JOBS    
DRAWBACK: SETUP CAN BE TIME CONSUMING    
MARKET SURVEY    
KEY PLAYERS    
FLEXOGRAPHIC PRINTING INKS MARKET, BY APPLICATION    
FLEXOGRAPHIC PRINTING INKS MARKET, BY REGION    
COMPETITIVE MARKET SHARE    
MACHINERY SUPPLIERS    
RAW MATERIAL SUPPLIERS    
INK    
SUBSTRATE    
MACHINERY PHOTOGRAPHS    
RAW MATERIAL PHOTOGRAPHS    
PRODUCT PHOTOGRAPHS    

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)