Manufacturing, Print, and Graphics
Laminations and Coatings
Tetra Pak cartons are made up of three materials that together result in a very efficient, safe and light weight package. Each material provides a specific function.
77% Paper – to provide strength and stiffness
18% Polyethylene – to make packages liquid tight and provide a barrier to micro organisms
5% aluminium foil – to keep out air, light, and prevent changes to the flavour. Anything that can cause the food to deteriorate.
Biodegradable coated papers.
Most of the paper used for packaging in quick-service restaurants is treated with materials that provide moisture and grease resistance.
Petroleum wax-based or low-density polyethylene (LDPE) coatings are typically used for moisture resistance,
while fluorocarbon-derived treatment are sued for grease resistance, either alone or in combination with other coatings.
Waxes
The wax is stored and transported in solid blocks and has to be pre-heated similar to hot melt adhesives to obtain the correct viscosity to flow. The wax cools and adheres to the substrate.
The gravure coating process relies on an engraved roller running in a wax coating bath. The engraved dots or lines in the roller are filled with wax coating. The excess coating is wiped off by the Doctor Blade and the coating is deposited onto the substrate as it passes between the engraved roller and pressure roller.
Offset Gravure is common, where the coating is deposited on an intermediate roller before transfer to the substrate.
Immersion Coating
In this simple process, the substrate is dipped into a bath of the coating, which is normally of a low viscosity to enable the coating to run back into the bath as the substrate emerges.
This process is frequently used on porous (absorbing) substrates.
Metering Rod (Meyer Bar) Coating
In this coating process, an excess of the coating is deposited onto the substrate as it passes over the bath roller. The wire-wound metering rod, sometimes known as a Meyer Bar, allows the desired quantity of the coating to remain on the substrate. The quantity is determined by the diameter of the wire used on the rod.
This process is remarkably tolerant of non-precision engineering of the other components of the coating machine.
Curtain Coating In the Curtain Coating process, a bath with a slot in the base allows a continuous curtain of the coating to fall into the gap between two conveyors. The object to be coated, such as a door, is passed along the conveyor at a controlled speed and so receives the coating on its upper face.
Slot Die (Slot, Extrusion) Coating In the Slot Die process, the coating is squeezed out by gravity or under pressure through a slot and onto the substrate. If the coating is 100% solids, the process is termed ‘Extrusion’ and in this case, the line speed is frequently much faster than the speed of the extrusion. This enables coatings to be considerably thinner than the width of the slot.
Gap Coating (Knife Over Roll, etc.) This process relies on a coating being applied to the substrate which then passes through a ‘gap’ between a ‘knife’ and a support roller. As the coating and substrate pass through, the excess is scraped off.
This process can be used for high viscosity coatings and very high coat weights, such as plastisols and rubber coatings. There are innumerable variants of the relatively simple process which is rugged, hard-working and somewhat inaccurate.
Air Knife Coating A simple process where the coating is applied to the substrate and the excess is ‘blown off’ by a powerful jet from the air knife. This procedure is typically used for aqueous coatings and is particularly noisy. 
When petroleum wax based coatings are used with hot foods, they are typically modified with high melting temperature synthetic waxes to provide the required high temperature properties to prevent the wax melting into the food.
Wax and polyethylene are also used as laminates in packaging constructions containing more than one paper layer.
Smart Materials
1. Holographic Image2. Carrier foil
3. Wax
4. Adhesive
They are applied using a Hot Foil Press.
· The card is positioned on a platen bed
· The holographic foil is fed between the card and heated die.
· The heated die presses the foil onto the card.
· The heat melts the wax and separates the hologram from the carrier foil
· The pressure applies the adhesive backend hologram material to the card.
Holograms are used for the following:
· Effects on CD and DVD covers
· Effects on paperback book covers. Advertisers report over 100% increase in sales lines with holographic packaging.
· Security – holograms halted the increase in credit card and ticket counterfeiting. Widely used on packaging to protect software, CD, and DVDs
· Give the buyer a sense of authenticity.
Composites
Composite materials consist of two or more materials combined.
The individual materials that make up a composite are called constituents.
Paper and inks are composite materials.
Printing Inks
Modern lithographic printing inks are formulated with very complex recipes. However, they can be considered to have three basic ingredients.
1. Pigment – This gives the colour
2. Vehicle – This is a varnish made up of resin, solvent and driers. These are semi transparent and carry the pigment to the substrate, and provide adhesion to the substrate’s surface.
3. Additives – They include metal soap driers, wetting agents, waxes and anti set off paste.
CAD (Computer Aided Design) and CAM (Computer Aided Manufacture)
· 3D Modelling of packaging nets to determine assembly and dimensions are correct. (Using computer software programme for driving a plotter.)· It can be used to colour proof artwork to determine aesthetic and functional requirements.
CAD is an important industrial process because:
· It can test and modify ideas in 2D
· Simulate 3D products on screen.
· Show product to client virtually before manufacturing samples.
· Reduction in time and costs.
CAM
Cam is used in print manufacturing by:
· Using programme software for production lay planning and automatic cutting of board (Plotters).
· Using of vinyl cutters for sign making.
· Using lasers for making printing plates.
· Operation and control of printing press.
Benefits to the consumer if the manufacturer uses CAM:
· Accuracy. E.g. the product is the right size and the packaging fits together, therefore securing and protecting the product inside.
· Consistency in the standard of product.
· Lowers the cost of complex products.
Benefits to the manufacturer if using CAM:
· Reduced lead times because concurrent manufacturing can occur and more than one product can be produced.
· Higher production rates because it will be produced faster using computers and it is quicker to set the machine up again in-between jobs.
· Lower workforce requirements which means that more money is saved in wages and taxes that have to be paid on employees.
· Better quality of output because there is a reduced likelihood of human error.
· Reduced waste and processing costs – less setting up waste and production waste as operation of the press is simplified and quicker to respond.
· Data from a manufactured job can be stored and therefore previous machine settings can be reloaded into machine meaning that jobs can be repeated more easily.
Manufacturing activities where a traditional method has been replaced:
· Traditional method – Manually operating the printing press and making changes to it physically. Modern Method, Use of CAM – For operating the printing press. Advantages – Reduced lead times, easier control of the printing press.
· Traditional Method – Cutting out by hand. Modern Method (Use of CAM) – Setting up the machine plotter. Cutting out individual shapes directly from computer. Advantages – Accuracy, better quality.
ICT
· Database· Internet
· Intranet
ICT used for handling information include:
· Spreadsheets
· Databases
· Excel
· Access Database
Communication Technology
Communication technologies which are used to transfer information between suppliers and manufacturers include:
· ISDN (Integrated Services Digital Network, a digital telephone line which allows very rapid, reliable, low cost transmission of data between computers.)
· Extranet
· Video Conferencing
Old Technology Replaced by Communications Technology and the benefits.
· Spreadsheets and databases have replaced Manual Calculations and manipulation of data.
o The benefits are accuracy and reliability of calculations and data. Easier editing of data and calculations.
· Email has replaced letters and faxes.
o The benefit is faster delivery of messages, less chance of it being lost, more secure, and less chance of misinterpretation of messages.
· CAD and DTP have replaced manual designing on paper.
o Benefits are easier transportation of design and less likely to be lost or damaged.
· Video Conferencing has replaced in-person meetings.
o The benefit of this is less traveling costs and not cost for venues. Easier for people to make the meeting and reschedule.
The benefits of manufactures using ICT to talk to their suppliers are:
· Speed and accuracy of communication.
· It enables JIT (Just-In-Time) manufacture which reduces the need for stock and cost of storage.
· Enables QR (Quick Response) manufacturing to make it easier to meet consumer demands.
Benefits of retailers using ICT to talk to manufacturers are:
· Fast ordering of popular styles/colours
· Fast delivery of products with QR to consumer demands.
· Increased good reputation of retailer because of constant availability of stock which will result in improved sales.
Communications technology used to transfer sales information from printing retailers to manufacturers include:
· EPOS (electronic point of sales) tills to record, sort and store sales information in database.
o Calculate Stock levels using bar coding and being able to order fast selling products electronically.
· Use of Email to send data on sales.
Use of ICT at the Marketing Stage of manufacture.
· Analyse market research data in database about customer preferences.
· Use Spreadsheets to calculate the cost of the resources required for the job.
· Plan marketing campaign using DTP, CAD, Image manipulation software.
· Use Internet and Website for marketing.
Benefits to Manufacturer of using ICT in marketing stage.
· Speed and Accuracy of analysis to establish marketing base.
· Accuracy and flexibility of cost requirements.
· Ability to plan marketing.
Advantages to manufacturer using ICT at the production planning stage:
· All planning data held in a database is available to the whole production team.
· Easy and fast access to planning data.
· Easy access to feedback so you can identify when change are necessary.
· Documents each stage of manufacture enabling production standards to be met.
Use of ICT in Packaging and Dispatch.
· Electronic monitoring of packaging processes using electronic tagging and labelling.
· Use of bar codes to monitor packaging/dispatch cards.
Advantages of ICT to a Manufacturer who operates worldwide.
· Import data from around the world through electronic links to design office at head office.
· Sending data to client for approval anywhere in the world.
· Electronic communication of manufacturing data to overseas manufacturing facility.
· Links between business partners in different locations using email, internet and video conferencing.
· Design in one location and manufacture in another where labour is cheaper.
· Lower costs for manufacture available. E.g. Cheaper materials, labour etc.