Detailed Project Report on flexible packaging (rotogravure printing)

FLEXIBLE PACKAGING (ROTOGRAVURE PRINTING)
[CODE NO.3239]


Flexible packaging products include candy wrappers, bags for cookies, snack foods, fresh and frozen products, diapers and personal hygiene products, envelopes for powdered soups and juices, flexible bags for ketchup and mayonnaise and for cleaning products such as laundry detergents, labels for beverage bottles, peel-off lids and labels for yogurt containers and wrappers for ice cream products. All of the Company’s products are manufactured in accordance with international requirements and customized to meet individual customer specifications.

Production of flexible packaging products begins in pre-press. The main pre-press process involves the digital design for packaging graphics, including color separation, text and layout. There are two forms of printing: rotogravure and flexography. The rotogravure printing process involves diamond-etching a cylinder for each product’s color layer. It is appropriate for high-quantity orders. Flexographic printing process requires a polymer plate (one for each color) with the design to be printed, that is wrapped around a metallic cylinder.

Traditionally, machinery and equipment requirements for rotogravure printing have been greater than for flexographic printing, and as a result, flexographic printing has been more commonly used. While flexographic printing quality has traditionally been inferior to the rotogravure method in terms of printing clarity and quality, these differences have been diminishing over time as the quality and equipment investments in the flexographic printing method have increased.


COST ESTIMATION

Plant  Capacity                                                             :    4.00 Ton/day      
land & Building (1000 Sq.Mtr)                                   :    Rs. 1.18 Cr
Plant & Machinery                                                        :    Rs. 1.25 Cr
Working Capital for 1 Month                                      :    Rs  2.12 Cr
Total Capital Investment                                             :    Rs. 6.43 Cr
Rate of Return                                                              :    30%
Break Even Point                                                          :    49%


INTRODUCTION    
PROPERTIES    
PERMEABILITY RATES OF SELECTIVE PLASTIC PACKAGING MATERIALS    
RADIATION STABILITY OF POLYMERS    
PHYSICAL PROPERTIES OF PLASTICS USED IN FOOD PACKAGING    
CHEMICAL AND PERFORMANCE PROPERTIES OF PLASTICS    
USES & APPLICATION OF FLEXIBLE PACKAGING    
PROPERTIES AND CHARACTERISTICS    
INNOVATIONS AND ADVANCEMENT IN FLEXIBLE PACKAGING    
METALIZED FILMS    
MODIFIED ATMOSPHERE PACKAGING    
ACTIVE PACKAGING    
EDIBLE AND SOLUBLE FILMS    
INTELLIGENT PACKAGING    
OVERVIEW OF FLEXIBLE PACKAGING    
PROCESSING OF DIFFERENT TYPES OF FILMS    
BLOWN FILM    
CAST FILM    
COEXTRUSION    
ADVANTAGE OF CO-EXTRUDED MULTILAYER FILM    
RAW MATERIALS    
PROPERTIES AND CHARACTERISTICS OF MULTI LAYER CO-EXTRUDED FILM    
5 LAYER FILM    
EVOH BASED 5 LAYER FILMS    
MOLECULAR STRUCTURE OF EVOH RESINS    
PRESERVING FOOD QUALITY    
PROTECTING THE ENVIRONMENT    
RESISTING INDUSTRIAL CHEMICALS    
SUPERIOR GAS AND MOISTURE BARRIER PROPERTIES    
BARRIER TO FLAVOUR PERMEATION    
BARRIER TO AROMA PERMEATION    
RESISTANCE TO SOLVENTS    
UV-RESISTANCE    
EXCELLENT FLEX-CRACK RESISTANCE    
GOOD PRINTABILITY    
GAS BARRIER PROPERTIES OF EVOH VS OTHER POLYMERS    
HOW PACKAGING HAS CHANGED    
MARKET SURVEY    
FIGURE: PLASTIC PACKAGING INDUSTRY OUTLOOK (USD BN)    
FUTURE DEMAND FOR FLEXIBLE LAMINATES    
LAYER FILM    
INDIA AS MANUFACTURER BASE FOR GLOBAL MARKET    
TOTAL POLYMER CONSUMPTION 2012-13    
TOTAL INSTALLED CAPACITY     
PRODUCTION OF COEXTRUDED MULTILAYER FILM    
GLOBAL MARKET OF FLEXIBLE PACKAGING    
FIGURE: SHARE OF PACKAGING MEDIUMS    
FIGURE: USE OF POLYMERS IN FLEXIBLE PACKAGING    
FLEXIBLE PACKAGING MARKET DYNAMICS    
TABLE: NEW PRODUCTS IN FLEXIBLE PACKAGING    
CHANGING CONSUMPTION PATTERNS    
ADVANTAGE OF FLEXIBLE LAMINATES    
KEY DRIVERS OF PACKAGING INDUSTRY    
FIGURE: INDIAN RETAIL INDUSTRY OUTLOOK (USD BN)    
FIGURE: INDIAN FOOD & BEVERAGE INDUSTRY OUTLOOK (USD BN)    
FIGURE: PACKAGED FOOD SPEND (PER CAPITA)    
FIGURE: GLOBAL SEGMENT BREAKUP OF PACKAGING MATERIALS (%)    
INCREASED FOOD SAFETY, QUALITY & SHELF LIFE:    
INNOVATIONS IN PACKAGING:    
FIGURE: END-USAGE SHARE OF PLASTIC PRODUCTS (%)    
FUTURE OPPORTUNITIES    
CONCLUSIONS    
MANUFACTURING PROCESS OF FLEXIBLE PACKAGING    
PROCESS FLOW DIAGRAM    
METHOD OF POUCH MAKING    
ROTOGRAVURE PRINTING PROCESS    
DETAILS OF ROTOGRAVURE PRINTING    
GRAVURE - PRINTING PRESSES    
COMPOSITION OF SOLVENTLESS LAMINATOR    
DETAILS OF SOLVENT FREE LAMINATING PROCESS    
TYPICAL SOLVENT FREE LAMINATOR    
TYPICAL SOLVENT FREE METER-MIX    
BIO-FILM CONSIDERATIONS DURING SOLVENT FREE LAMINATION    
COMPARISON OF LAMINATION PROCESSES    
TECHNIQUES OF CO-EXTRUSION    
VARIOUS CO-EXTRUDED FILMS:    
PLANNING AND SCHEDULING IN FLEXIBLE PACKAGING MANUFACTURE    
PLANNING AND SCHEDULING WORKBENCHES    
QAD QMS (QUALITY MANAGEMENT SYSTEM)    
AUTOMATION SOLUTIONS    
ENVIRONMENTAL IMPACT OF FLEXIBLE PACKAGING    
SOLVENT USE AND TREATMENT    
ENERGY USE    
PRINTING    
PROCESS LOSSES    
BLOWN FILM EXTRUSION PROCESS    
SUPPLIERS OF PLANT AND MACHINERY    
SOLVENT LESS LAMINATING MACHINE    
POUCH MAKING MACHINES    
ROTOGRAVURE PRINTING MACHINE    
SUPPLIERS OF RAW MATERIALS    
ADHESIVE    
PRINTING INKS    

                            
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET