GRAVURE PRINTING TECHNOLOGY A TO Z

and Quality Trouble Shooting Tips

Press, impressively!
ORIENT SOGYO CO., LTD.
Hidenori Harada
at Hotel Mulia Senayan - Jakarta
Nov 19, 2013
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GRAVURE PRINTING TECHNOLOGY A TO Z
What is happening in Japan Gravure printing
industry?
What do we foresee in Indonesian Gravure
printing industry?
ORIENT new direction & proposals
Gravure Printing : A to Z
Principal of Web handling and Gravure Printing
Quality trouble shooting Tips
INTRODUCTION BUSINESS ENVIRONMENT
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*S$J+
, 100"1 a( o- Nov1., 2013
, //"0 a( o- Nov30, 2011
JAPAN GRAVURE - BUSINESS ENVIRONMENT
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Ja1an Gravure +rintin& %((o2iation 3JG+%4 56e)eral7
8%NTO 5Tokyo area7 )i(tri2t
TO8%I 5Na&oya area7 )i(tri2t
8%NS%I 5O(aka area7 )i(tri2t
an) (o on9
,, Over 300 :i) - (:all (i;e 2o:1anie( <oine)==
5in2lu)in& Su11lier(7
JAPAN GRAVURE BUSINESS ENVIRONMENT
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E(ta>li(' ? %2tivitie( an) @ene-it o- JG+%
%&ain(t TAo Me&a-(i;e 2o:1anie( 5$ B T7
Ne&otiate 5#o>>yin&7 Ait' Govern:ent
@ene-it ? >ank loan(
!lai: B Su&&e(tion( to +a2ka&in&
2u(to:er(Cu(er(
JAPAN GRAVURE BUSINESS ENVIRONMENT
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%2'ieve:ent(
DO! e:it re&ulation
More t'an 30E re)u2tion -ro: year 2000=
FGreen +rintin& !erti-i2ate) 6a2toryG
Green +rintin& !riteria
H3 -a2torie( are !erti-ie)
5a( o- O2t 20137
Re&ular (e:inar( an)
#ea)er('i1 )evelo1:ent
INTRODUCTION GP ASSOCIATION
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!o::on to1i2( at JG+%
Ener&y Savin& 5e(1" Ele2tri2ity (avin&7
#a>or 'ealt'
!ar>on--oot 1rint 5#i-e !y2le %((e((:ent7
!ounter:ea(ure to S'ort-run <o>( an) +rivate @ran)
ite:(
JAPAN GRAVURE BUSINESS ENVIRONMENT
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I'at i( S'ort ? run <o> J
Hi&'-1re:iu: ('el-
+re:iu: ('el-
JAPAN GRAVURE BUSINESS ENVIRONMENT
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I'at i( S'ort ? run <o> J
Only 2k& ri2e 2on(u:1tion=
Jo> >e2o:e S'orter t'an ('orter 2000:C<o> JJ
JAPAN GRAVURE BUSINESS ENVIRONMENT
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I'at i( +rivate >ran) ite:( J
+rivate >ran) ite:( are (ol) 2'ea1er t'an National >ran) ==
JAPAN GRAVURE BUSINESS ENVIRONMENT
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<Summary>
Environmental reulation !
Co"t!#i"e $om%etition
Su%er S&ort!run
'rivate (rand
)u"ine"" *eat&er +ore$a"t
Highest : 20
Lowest : 10
Chance of rain : 30%
INDONESIAs GDP per Person
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INDONESIA BUSINESS ENVIRONMENT
EK1e2te) 2on(tant &roAt'
an) Dery ra1i) In-lation
INDONESIAs GDP growth per Person
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INDONESIA BUSINESS ENVIRONMENT
Ri2' natural re(our2e(, 200:illion 1o1ulation=
L 21th century Most attractive investing Target!
Raise values of Country, Companies and People NOW
PRODUCTS DESIGN BACKGROUND
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PRODUCTS DESIGN BACKGROUND
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Japanese unique mentality, culture Man & Method
You can BUY machine & material but
PRODUCTS DESIGN BACKGROUND
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Output (machine) is reflection of Cultural background
European Japanese ~ Asian
Top-down decision making Bottom-up activity
Conquering (Hunting culture) Co-exist (Farming culture)
Bigger size Factory Compact size Factory
Safety & speed oriented Operation oriented
Industrial standard Contract
absolute
Human (customer) relationship
Outlook & theory oriented
Design
Practical & experience oriented
design
Drastic change (break-through) KAIZEN change
Automation is cool! Automation + Manual
Trolley "y"tem &a" (een very $ommon
Gravure $ylinder i" S&a,ted ty%e
ABOUT EUROPEAN DESIGN
Rei"ter!$ontrol #it&in t&e "ame
rou% -)O)ST.
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ABOUT EUROPEAN DESIGN
/ *0H 1 HELIOST2R -3uote ,rom *e( "ite. /
/ CI Drum +le4o -+05. /
Con$entrated O%eration de"6
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MaK S1ee) H00:C:in
Ie) Ai)t' M .00 - 1300::
2ir -7e$&a. "&a,t i" $ommon
+or #e( roll loadin
*ide #e( +le4o
CI drum i" $ommon
ABOUT EUROPEAN DESIGN
HP Indigo 20000
*e( #idt& 89:mm
S%eed 9;.9m<min -=$olor.
Cli$6 C&are di,,erent %rint de"in (ut "ame e4%en"e
Cu"tomer 1 >)rand!o#ner? $an (e a %rintin &ou"e@
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7iddle #e( ,or +le4i(le
'a$6ain
RE : ORIENT SOGYO CO., LTD.
Innovative Research and Development
a) Twin-Impression Dry laminator
b) Triple-Cylinder built-in Gravure printing press
c) Computer-Color Matching (CCM) system
d) Compensator-free Sectional Drive Type VLS
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Not al#ay" "u$$e"", (ut never "to% CHALLENGING!
A AA ADVANTAGES DVANTAGES DVANTAGES DVANTAGES OF OF OF OF T TT TYPE YPE YPE YPE VLS ! VLS ! VLS ! VLS !
Very precise Start up (initial) register
Sectional Drive System bring Quality and Waste-minimizing Sectional Drive System bring Quality and Waste-minimizing
Advantage (1)
Advantage (2)
Advantage (3)
Quick response register at speed increasing
Stable web running even at Web splicing
Accurate and reliable performance at Constant speed operation
Advantage (4)
RE : ORIENT SOGYO CO., LTD.
Innovative Research and Development
e) Water-base Gravure Printing press OSG-SDX VLS
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FUJITOKU (Nagoya) highly reputed in Water-base Gravure
Golden Cylinder 2#ard
RE : ORIENT SOGYO CO., LTD.
Innovative Research and Development
e) Energy-Saving dryer K2 Dryer
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Dryin Enery $on"um%tion 1 a(out A:B do#n@
@otto: >loAer
58%NR* >loAer7
@otto: >loAer
58%NR* >loAer7
K2 DRYER ~ ENERGY SAVING DRYER ~ (PR)
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K2 Dryer Conditions of Running Cost Simulation @ Max 250m/min
Conventional K2 dryer
Heat source No of colors 8 8
Max temp. 60 () 63 ()
Air volume 72 m3/color 70 m3/color
(kcal/h) 224,787 (*Cir 15%) 131,047 (kcal/h)
Total of Heat volume 261 kw 152 kw
Total of Supply+Exhaust blower 66 (kw) 46 (kw)
Operational hours (H/day) 24
Operation days (days/year) 300
Net Production rate (%) 60%
Net Operational (H/year) 4,320
Electric unit price (JPY/kwh) 18
Energy cost (JPY/year)
Gap
Electric cost (JPY/year)
Gap
Yearly Sum of gaps /year
IMPORTANT

Local Exhasut is separate route

Bottom zone temerature is depending on Top zone temperature

This simulation is reference only. ORIENT does NOT provide any Warranty for the practical results.
JPY 10,015,492
JPY 20,324,946 JPY 11,849,102
JPY 5,132,160 JPY 3,592,512
JPY 8,475,844
JPY 1,539,648
Approx.
40% energy saving!!
Approx 30% saving blower
max capacity!!
f) Split System
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RE : ORIENT SOGYO CO., LTD.
e.g. 8-color split type
4+4, 5+3, 6+2, 7+1 color at the same time!
or even Starlight mode operation
~ This is the technology based on Well sophisticated Web
handling and Sequential program
Ne# Trend in INDONESI2 -Sout& Ea"t 2"ia. 7ar6et
RE : ORIENT SOGYO CO., LTD.
KAIZEN base improvement
Fire Accident measurement
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RE : ORIENT SOGYO CO., LTD.
KAIZEN base improvement
New Mechanical chuck for minimize paper core damage
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Ne# C&u$6in met&od o, 'a%er $ore
RE : ORIENT SOGYO CO., LTD.
KAIZEN base improvement
Face to Face Cylinder chucking
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+or Ea"y ta%e re#indin
+or le"" in6 inva"ion in"ide o, $ylinder"
+or ,a"ter $leanin at $ylinder ,lane
GRAVURE PRINTING QUALITY PROBLEMS MAP
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Color deviation
Structural / Inevitable / Complex
Not
serious
Very
Serious
Doctor streak
Static squeeze out
Unsmooth Half tone
Mismatch register
Pitch variation
Foreign matter Solvent retention
Wrinkle Wrinkle Wrinkle Wrinkle
Blocking
Fogging
Accidental / Unpredictable / Simple
Ink splash
Trapping Trapping Trapping Trapping
TYPICAL PROBLEM(1) : MISMATCHING REGISTER
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TYPICAL PROBLEM(1) : MISMATCHING REGISTER
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Sy:1to: +otential 2au(e( B !ounter:ea(ure(
I:a&e( look in-erior
an) loo(in&
re2o&nition o-
1a2ka&in&
a7 6il: elon&ation, *nevenne(( knoA -il:
>7 Me2'ani2al re(i(tan2e @uy ORIENT
27 +oor 2ylin)er a22ura2y 52ir2u:7 %i: >oun2e C
roun)ne(( le(( t'an 0"00::
)7 I:1ro1er Ten(ion 2ontrol( re-" +it2' variation
e7 EK2ee)in& te:1erature (ettin& Solvent retention
-7 Mark( :i(-(en(in& et2
IMPRESSION EXPANSION
6il: Ai)t'
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IMPRESSION NIP
I:1re((ion tou2' at RIGHT an&le to Gravure 2ylin)er
Nor:al
%>nor:al
Evenly 1re((uri;e)
Sta>le re&i(ter
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SKEWING ROLL (ECCENTRIC ROLL)
Skewed
zero
narrower
wider
center
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FREE ROLL SLIPPING
When Line speed increase Film speed Roll rotation speed
B side tension get tighten
When line speed decrease Film speed Roll rotation speed
B side tension get loosen
B A
Impression rolls, guide rolls etc
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$!NA&I" BALAN"E
0"0H3N1"0/ , 1"O13&
I, dynami$ (alan$e i" %oor C
Cau"in ma$&ine vi(ration, me$&ani$al re"i"tan$e
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/ N2G2H272 made Dynami$ (alan$er i" o%erated in ORIENT/
WEB TENSION CHART
8in) T'i2k *nAin)ner In-ee) Out-ee) ReAin)er RI Ta1er
O++
20P .0N 100N 120N 00N 2030
30P 100N 120N 1H0N O0.0N 2030
H0P 120N 1H0N 1O0N 100120N 2030
00P 1201H0N 1O0N 1.0N 1201H0N 2030
+ET
12P 100120N 1201O0N 1201O0N /0.0N 1020
1OP 100100N 100200N 100200N .0100N 1020
N
12P .0N 120N 120N O0.0N 2030
10P 100120N 1201H0N 1201H0N /090N 2030
e"&" A'en Ae> Ai)t' i( 1000::
Only -or Re-eren2e
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SNA'E R(N
"o))ee *rea+
additi%e
~ Edge film top and bottom : different diameter, color and
density
OPP "PP
"ause )ilm run not straight
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TYPICAL PROBLEM(2) : DOCTOR STREAKING
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%22u:ulate)
(lu)&e
Press, impressively
Doctor Doctor Doctor Doctor
Do$tor dire$tion
TYPICAL PROBLEM(2) : DOCTOR STREAKING
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Sy:1to: +otential 2au(e( B 2ounter :ea(ure(
Streak line( a11ear
on t'e 1rinte) i:a&e"
T'e 1o(ition :ay >e
ran)o:ly or
re&ularly
a7 6orei&n :atter (tu2k >etAeen >la)e B 2ylin)er
A'ere are t'o(e -orei&n :atter( -ro:J
a7 Not -iltere) Aell )urin& ink 2ir2ulation
>7 Ink re(in 2on)en(ation 5e(1" re2y2le) ink7, 1oor ink
2ir2ulation
27 +oor ink re-Aettin&
E(1" @la2k 'al-
tone :ore likely
(treak(
Ink (1la(' le-t on
:a2'ine re(olve into
ink-tray all o- (u))en
TYPICAL PROBLEM(3) : MISSING DOT
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Dot re%rodu$e D Sta(le 0 E,,i$ient in6 tran",er Dot re%rodu$e D Sta(le 0 E,,i$ient in6 tran",er
TYPICAL PROBLEM(3) : MISSING DOT
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Sy:1to: +otential 2au(e( B 2ounter :ea(ure(
Gravure loAer E
(2reen )ot( 2an not
>e 1rinte) at all or
(ta>ly"
+rinte) i:a&e 'a(
1oor &ra)ation or
2olor re1ro)u2in&
17 $o2tor an&le, >la)e 2onta2t 1oint Mat2' At #ine (1ee)
27 +oor -il: Aetta>ility !orona treat
37 *neven I:1re((ion ru>>er 'ar)ne((, 1re((ure
H7 Ine--i2ient inkin& to &ravure 2ell( !ell ('a1e C Too 'i&'
Di(2o(ity - 6urni('er u(e
07 I:1ro1er Solvent ty1e :iKture rate Too -a(t )ry
O7 +rintin& roo: environ:ent %ir-2on)itione) roo:
TYPICAL PROBLEM(4) : BLOCKING ROLL WRINKLE
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Sy:1to: +otential 2au(e( B 2ounter :ea(ure(
6il: an) -il: &et
(tu2k a-ter reAoun)"
Ink (ur-a2e )a:a&e(
t'e 1rinte) i:a&e, or
e--e2t( to t'e
-olloAin& 1ro2e((
*nAin)in&"
a7 Ink not )rie) (u--i2iently, or )rie) (ur-a2e only"
Rea)<u(t no;;le (1ee), te:1" or line (1ee)"
>7 Not enou&' -il: 2oolin& >e-ore reAoun)"
Retaine) 'eat in reAoun) Ae> roll 2au(e( eK2e((
('rinka&e C 1'y(i2al (tre(( in t'e Ae> roll"
27 Too 'i&' retain ten(ion reAoun) Ae> roll
EK2e(( ('rinka&e an) 1'y(i2al (tre(( in t'e Ae> roll"
QRe- M $ry la:inationR
Retainin& Ae> ten(ion or 'eat 5uneven ten(ion >etAeen
Main an) Sealant Ae>7
Ie> Arinkle, tunnelin&, or tele(2o1in& )urin&Ca-ter
!urin&"
TYPICAL PROBLEM(4) : SOLVENT RETENTION
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Sy:1to: +otential 2au(e( B 2ounter :ea(ure(
Solvent retention
a-ter 1rint or
la:inate i( not in
alloAan2e value
17 $ryer 2a1a>ility #ine (1ee) not :at2'
6ilter 2lo&&in& 2au(e no;;le (1ee) )e2rea(e
27 Gravure 2ell )e1t' vi(2o(ity (olvent :iKture rate
Toluene i( t'e la(t (olvent to >e )rie)"
37 Solvent tu2k( into -il: eK2e((ively
H7 %)'e(ive tu2k( into ink eK2e((ively
07 Too 'i&' 2oatin& volu:e too loA vi(2o(ity
Excess air velocity & temp.
Medium to High Air
velocity and temp.
Ti1( -or e--i2ient )ryin&
17 Not eK2ee)in& 'eat 2'ar&e
27 Not eK2ee)in& air velo2ity
TYPICAL PROBLEM(5) : STATIC
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Sy:1to: +otential 2au(e( B 2ounter :ea(ure(
In-erior i:a&e >y ink
(Suee;e out" EK2e((
(tati2 :ay 2au(e
(1arkin&"
17 !onta2t 5e"&" Ie> runnin&7
27 6ri2tion 5e"&" Ni1 roll, 6urni('er, S:oot'in&, S1ee) a22el"7
37 +re((ure 5e"&" Ni1 roll, RI tou2' roll, in(i)e Ae> roll7
H7 Relea(e 5e"&" Ni1 roll, Ae> runnin&7
07 Roo: 'u:i)ity environ:ent

%7 Re)u2e Ru>>er roll

ru>>er , 2'ara2ter 2'an&e >y ti:e
, Not 1er-e2t 2'oi2e
@7 Eli:inate M Sel- )i(2'ar&e %2tive
, +er-or:an2e 2'an&e >y ti:e N Sa-ety 52o(t7
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/ *&ole Stainle"" +loor -7irror!,ini"&. /
2ir!$on outlet" and Dry!
+o "%rin6le noEEle"
Clean ,loor immediately #&en In6 dri%%ed. Clean ,loor immediately #&en In6 dri%%ed.
'i$ 1 SEI5O Co.,Ltd. -T"u6u(a +a$.
Typical problem(5) : Static
TYPICAL PROBLEM(6) : FOREIGN MATTERS
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Sy:1to: +otential 2au(e( B 2ounter :ea(ure(
O><e2t( inva)e an)
2onta:inate t'e
-il:, 1rinte) i:a&e,
or :a2'ine"
5Hair, )u(t(, >u&(7
17 6ro: o1erator
27 6ro: -a2tory environ:ent C -loor 1lan
37 6ro: 1reviou( 1ro2e((, <o>(
H7 6ro: :a2'ine 5Ga( >urner, air -ilter, )ryer, i:1re((, oil7
07 6ro: 6il:
O7 6ro: Ink, re(in
/7 6ro: $o2tor >la)e, Ta1er-2on, +a1er-2ore
XPRESS WITH S.W.I.M. O!EPT
<Xpress Main feature
Machine speed 200m/min
Web width 300-620m
Structure Inline Unit type
Print repeat 280-600mm
Drive system Sectional drive
Kiss touch All AC servo motor
Drying : By Hot air blowing
Dimension (L)14000mm x(W)2800mm
x(H)2800mm (at 6C straight)
(*excld. blowers)
Inline Unit type Mid-web FLEXO printing press
Xpress = = = = Unknown Unknown Unknown Unknown X XX X Printing Printing Printing Printing Press Press Press Press
= = = = Orient Express Orient Express Orient Express Orient Express ( (( (Train between Asia to Europe Train between Asia to Europe Train between Asia to Europe Train between Asia to Europe) )) )
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N NN NEW EW EW EW ERA ERA ERA ERA OF OF OF OF F FF FLEXO LEXO LEXO LEXO P PP PRINTING RINTING RINTING RINTING P PP PRESS RESS RESS RESS
S.W.I.M. O!EPT
Unique concept FLEXO can co-exist with Gravure
Not CI drum, Not UV
!" #$%&!'!m!t (rom ORIENT, )#*#
Su*!r +%ort ru

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I,&! u&t
W#t!r -#+!d &. M&d "&dt% "!-
EXPAN/ 0LEXIBLE PACKAGING /EMAN/S EXPAN/ 0LEXIBLE PACKAGING /EMAN/S
New key : New key : New key : New key : [ [[ [R RR Re ee e- -- -active idea active idea active idea active idea] [ ] [ ] [ ] [P PP Premium marketing remium marketing remium marketing remium marketing] ] ] ]
And And And And [ [[ [L LL Local ocal ocal ocal- -- -intimacy marketing] intimacy marketing] intimacy marketing] intimacy marketing]

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<,ormer> Not ne2e((ary all t'e
1a2ka&in& )e(i&n Aoul) not >e2o:e
a2tual 1a2ka&e9
<Ne#> S'oAin& :ore 2'oi2e( to
!on(u:er an) t'ey Aill )eter:ine
A'at i( t'e >e(t=
MINIMUM QUANTITY OF BAGS SUPPLIED MINIMUM QUANTITY OF BAGS SUPPLIED
)UST IN TIME *r#$t&$! #t 0,!1&-,! P#$.#2&2
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(* )
GR"V#RE VS. $LEXO
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Flexo Flexo Flexo Flexo Gravure Gravure Gravure Gravure
Color- reproduce range /
Resolution
GRAVURE > FLEXO
Ink & Solvent usage
GRAVURE > FLEXO
(2) (2)
2.
3.
[] [] = 1



5.


XPRESS XPRESS
1.
2. ) )
GRAVURE VS. FLEXO GRAVURE VS. FLEXO
Pro+ #d Co+3 C# 2o !&t%!r4
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PRINTING SAMPLES PRINTING SAMPLES
M#$%&! '&!"&2 tour #r! #'#&,#-,! u*o r!5u!+t
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0LEXIBLE PACKAGING SEMINAR
AT HOTEL MULIA )AKARTA NOV 67, 896:
THANK YOU FOR LISTNING THANK YOU FOR LISTNING THANK YOU FOR LISTNING THANK YOU FOR LISTNING

t!r&m# .#+&%
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