QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING

TESTING PROCEDURES A. TESTING OF RAW MATERIAL. 1. a. b. c. 2. a. b. c. 3. a. b. c. d. e. 4. a. b. c. d. Testing of Grannules. Visual Testing of Grannules. Grade on Bag On Machine Testing of masterbatch. Visual Testing of Masterbatch. Let Down Ratio (LDR) determination of masterbatch. On machine of masterbatch. Testing of Ink Viscosity of ink. Colour shade of ink. Rub Test. Deep Freeze Testing of Inks for Milk Film. Oil Resistance Testing of Oil / T/P Inks. Testing of Other materials. Cylinder Testing. Corrogated Sheet Testing. Tape Testing. Core Testing.

B. IN PROCESS TESTING. 1. a. b. c. d. e. f. 2. a. b. c. 3. a. b. c. d. Testing of extruded film. Thickness of extruded film. Lay Flat Width of extruded film. % Elongation of extruded film. Carona Treatment Level on treated side of extruded film. Pigmentation of extruded film. Processing defects in extruded film Testing of printed film. Colour shade verification test. Printing defects in printed film. Scotch tape adhesion test. Testing of slitted film. Slitted size of slitted film. Core Inspection Test. Winding of Slitted Film. Finishing of slitted Film.

TESTING OF FINAL PRODUCT. a. Thickness Testing. b. % elongation Testing. c. Pigmentation level Testing. d. Processing defects during extrusion in film. e. Colour shade verification Testing. f. Printing defects in film. g. Scotch tape adhesion Test. h. Rub Test. i. j. Deep Freeze Testing of Milk Film. Oil Resistance Testing of Oil film.

k. Slitted size of film. l. Core Inspection of Rolls.

m. Winding of slitted film. n. Finishing of slitted film

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QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING

1. Testing of Grannules. a. Visual Testing of Grannules.

Purpose : To check visually status of grannules packed in bag. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of grannule bags to inspect are decided. They are selected at random & checked for any of the visible impurity present in the grannule or grannules are wet / having some moisture. b. On machine / Quality Testing of Grannules.

Purpose : To check quality of grannules by processing them on machine. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of grannule bags to inspect are decided. They are selected at random & processed on machine at standard Temp. & are checked for any of the processing defects like Gels, pinholes etc.

2. Testing of masterbatch. a. Visual Testing of Masterbatch. : Purpose : To check visually status of masterbatch grannules packed in bag. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of masterbatch grannule bags to inspect are decided. They are selected at random & checked for any of the visible impurity present in the masterbatch grannules or they are wet / having some moisture in it. *******

QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING

b. Let Down Ratio (LDR) determination of masterbatch. Unit : % Purpose : To determine % of masterbatch required to achieve required pigmentation. Procedure : Considering % of pigment present in that masterbatch grade, Kg of masterbatch req. per 75 Kg of grannules mixing is decided. Then that mixing is run on machine & sample of film with that masterbatch is compared with standard sample for pigmentation level / opacity in light by eyes. Then LDR of that masterbatch is decided. Formula : LDR (%) = Kg of masterbatch per 75 Kg of grannules X 100 / 75. c. On machine / Quality Testing of masterbatch. Purpose : To check quality of masterbatch grannules by processing them on machine. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of masterbatch grannule bags to inspect are decided. They are selected at random & processed on machine at standard Temp. & film is checked for any of the processing defects like Gels/ unmelted masterbatch particles, pinholes etc. 3. *******

QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING

Testing of ink. a. Viscosity of ink. : Unit : Seconds. Purpose : To determine viscosity of ink using Ford Cup Viscometer. Procedure : Outlet of viscometer is closed with thumb & ink whose viscosity is to be determined is poured into it untill ink overflows in viscometer. Now thumb at outlet is removed & time required to empty the viscometer is determined which directly gives

viscosity of that ink in seconds.

QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING

b. Colour shade verification test. : Purpose : To compare colour shades of printed film with standard film sample. Procedure : Printed film sample is taken & compared with std. Film sample to check that colour shade of sample & standard film sample are matching. c. Scotch Tape Adhesion Test. : Purpose : to check adhesion of ink on poly film using cello tape. Procedure : Printed film sample / sample with dried drawdowm of ink is taken. Cello Tape is sticked on ink adhesion area & pressed. Now this cellotape is pulled rapidly & observed closely for any ink trace is removed or not. d. Rub Test. : Purpose : To check that ink is not removed from polyfilm after rubbing it with tissue paper. Procedure : Printed film sample / sample with Drawdown of ink is taken. It is rubbed gently with tissue paper for one minute. Now it is checked whether ink is removed after rubbing or not. e. Deep Freeze Testing of Inks for Milk Film. Purpose : To determine Deep Freeze strength of Inks for Milk Film. Procedure : Printed Film sample / sample with drawdown of ink is taken & kept in Freezer for 12 Hrs. It is then removed & rubbed gently with Tissue paper to check whether after Deep freezing this sample ink is removed or not.
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QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING

22. Oil Resistance Testing of Oil / T/P Inks. Purpose : To determine Oil resistance of T/P Inks. Procedure : Printed Film sample / sample with drawdown of ink is taken & immersed in oil for 12 hrs. It is then removed, cleaned & rubbed gently with Tissue Paper Testing of other material. 23. Cylinder Testing : Purpose : To inspect circumference, length & design of cylinder. Procedure : Incoming cylinder is checked for length & circumference in Cylinder Specification Chart of that cylinder & for design in Design of that cylinder. Then Quality Inspection Remark is given in G. R. I. N. of that Cylinder. 24. Corrogated Sheet Testing : Purpose : To check length, width, no. of plies & quality of incoming sheet sample. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of samples to inspect are decided. They are selected at random & checked for length, width, no. of plies & quality as per standard sheet specification. Then Quality Inspection Remark is given in G. R. I. N. of that Cylinder.
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QUALITY PLAN FOR QA DEPT.

TITLE : PROCEDURES FOR TESTING Ref. : SEL-AM-P-M-13 / Rev. 01

25. Tape Testing : Purpose : To inspect incoming Tape as per standard tape sample specification. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of samples to inspect are decided. They are selected at random & checked for width & Quality as per standard Tape specification. Then Quality Inspection Remark is given in G. R. I. N. of that Cylinder. 26. Core Testing : Purpose : To inspect incoming core as per standard core specification. Procedure : As per Quality Plan for inspection (Lot size & sample size) no. of samples to inspect are decided. They are selected at random & checked for I. D., O. D. & quality as per standard core sample specification. Then Quality Inspection Remark is given in G. R. I. N. of that Cylinder.

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QUALITY PLAN FOR QA DEPT.

TITLE : QUALITY PLAN FOR INSPECTION ( LOT SIZE & SAMPLE SIZE) Ref. : SEL-AM-P-13/Rev. 01

FOR GENERAL INSPECTION ( IS 2500 PART II, TABLE I) TABLE A LOT SIZE INSPECTION LEVEL IV SAMPLE SIZE CODE LETTER 2 TO 8 B 9 TO 15 B 16 TO 25 C 26 TO 50 D 51 TO 100 E 101 TO 150 F 151 TO 300 G 301 TO 500 H 501 TO 1000 J 1001 TO 3000 K 3001 TO 10,000 L 10,000 TO ABOVE M TABLE B
INSPECTION LEVEL IV SAMPLE SIZE CODE LETTER SAMPLE SIZE

B C D E F G H J K L M For some special cases, please follow individual Quality Plan made by SEL.

3 4 5 7 10 15 25 30 35 40 50

QUALITY PLAN FOR QA DEPT.

TITLE : IN PROCESS QUALITY INSPECTION

For In Process Quality Inspection following different testings are done. Extrusion Dept. : a. Thickness of extruded film : b. Lay flat width of extruded film : c. % Elongation of extruded film. d. Carona Treatment level on treated side of extruded film : e. Pigmentation of extruded film : f. Processing defects in extruded film.

Above testings are done by following ways. f. a. Thickness of extruded film : It is done as per method 6 of Procedures for testing. Thickness of extruded film. : Unit : Micron. Purpose : To determine Thickness of film using Gaugemeter. Procedure : Film Sample is taken Its thickness at various points in lengthwise direction is checked with Gaugemeter & noted down. Now avarage of these thicknesses is determined which will give you avarage thickness of film. Formula : Avg. Thickness of Film = Sum of all thicknesses / no. of thickness points. g. Lay Flat Width of extruded film. : Unit : mm. Purpose : To determine Lay Flat Width of Film using Scale. Procedure : Sample of film is taken. Its length in Transeverse Direction is measured using scale which will give its Lay Flat Width.

h. % Elongation of extruded film. :

Unit : % Purpose : To detemine % Elongation of Film manually. Procedure : Sample of the film is taken. 1 cm marking is done exactly at the centre of the Film. Now Film sample is pulled in opposite directions at two ends of the film steadily untill it breaks. Now extended length of marking of the film is measured using scale. % Elongation of the film sample is determined using following formula. Formula : % Elongation = (Change in length / original length) X 100 i. Carona Treatment Level on treated side of extruded film. : Unit : Dynes/cm. Purpose : To determine Carona Treatment Level of Treated Film using Dyne Solution. Procedure : Film Sample is taken. Treated Side is marked (Outer side of Film). Now Dyne Solution of different dyne levels is tried on this film on treated side. The treatment Level of the surface is indicated by the stability of a cm width solution applied on the surface for a two seconds duration. Based on this its Carona Treatement level is determined. Preparation of Carona treatment solution. CT Level desired Formamide

Cellosolve

36 dynes/cm 42.5% 57.5% 38 dynes/cm 54.0% 46.0% 40 dynes/cm 63.5% 36.5% 42 dynes/cm 71.5% 28.5% To this mixture aslight tinge of Rhodamine or Methylviolet can be added for colouration. j. Pigmentation : Purpose : To verify that pigmentation of pigmented film is same as that of std. Film sample of same thickness. Procedure : Pigmented Film sample is taken. Its pigmentation is compared with standard pigmented Film sample of same thickness in light. After close observation its pigmentation level is determined. b. Lay flat width of extruded film : It is done as per method 7 of Procedures for testing. c. % Elongation of extruded film. It is done as per method 8 of Procedures for testing. d. Carona Treatment level on treated side of extruded film : It is done as per method 9 of Procedures for testing.

e. Pigmentation of extruded film : It is done as per method 10 of Procedures for testing. f. Processing defects in extruded film : It is done as per method 11 of Procedures for testing.

QUALITY PLAN FOR QA DEPT.

TITLE : IN PROCESS QUALITY INSPECTION.

Printing Dept. k. Colour shade verification test. : Purpose : To compare colour shades of printed film with standard film sample. Procedure : Printed film sample is taken & compared with std. Film sample to check that colour shade of sample & standard film sample are matching. l. Printing defects in printed film. : Purpose : To check whether printed film sample is free from all printing defects. Procedure : Printed film sample is taken. It is compared with standard film sample in light to check printing defects like printing out, cylinder lines, colour lines, unwanted ink drops/ patches etc. m. Scotch Tape Adhesion Test. : Purpose : to check adhesion of ink on poly film using cello tape. Procedure : Printed film sample / sample with dried drawdowm of ink is taken. Cello Tape is sticked on ink adhesion area & pressed. Now this cellotape is pulled rapidly & observed closely for any ink trace is removed or not. n. Rub Test. : Purpose : To check that ink is not removed from polyfilm after rubbing it with tissue paper.

Procedure : Printed film sample / sample with Drawdown of ink is taken. It is rubbed gently with tissue paper for one minute. Now it is checked whether ink is removed after rubbing or not.

Above testings are done by following ways. a. Colour shade verification test. : It is done as per method 12 of Procedures for testing. b. Printing defects in printed film. : It is done as per method 13 of Procedures for testing.

Slitting Dept. o. Slitted size of slitted film. : Unit : mm. Purpose : To determine slitted size of slitted film using scale. Procedure : Sliteed film sample is taken. Its size is measured with scale which will give Slitted size of the slitted film. p. Core Inspection Test. : Purpose : To inspect paper core used for winding of slitted film. Procedure : Visual testing of core is done to check quality of core used to wind slitted film. q. Winding of Slitted Film. : Purpose : To inspect winding of slitted film. Procedure : It is checked visually that winding of slitted film is proper. r. Finishing of slitted Film. : Purpose : To inspect finishing of slitted film.

Procedure : Visual testing of slitted film is done to check whether slitting / cutting of film is proper or not & is free from trim.

a. Slitted size of slitted film. b. Core inspection test. c. Winding of slitted film. d. Finishing of slitted film.

Above testings are done by following ways. a. Slitted size of slitted film. : It is done as per method 14 of Procedures for testing. b. Core inspection test. It is done as per method 15 of Procedures for testing. c. Winding of slitted film. It is done as per method 16 of Procedures for testing. d. Finishing of slitted film. It is done as per method 17 of Procedures for testing.

QUALITY PLAN FOR QA DEPT.

TITLE : FINAL QUALITY INSPECTION.

Before doing packing of finished Film Roll for despatch as per Quality Plan for inspection (Lot size & sample size) no. of samples to inspect are decided & are selected for Testing at random.

These samples are then tested as following. s. Thickness Testing. t. % elongation Testing. u. Pigmentation level Testing. v. Processing defects during extrusion in film. w. Colour shade verification Testing. x. Printing defects in film. y. Scotch tape adhesion Test. z. Rub Test. aa. Deep Freeze Testing of Milk Film. bb. Oil Resistance Testing of Oil film. cc. Slitted size of film. dd. Core Inspection of Rolls. ee. Winding of slitted film. ff. Finishing of slitted film.

QUALITY PLAN FOR QA DEPT.

TITLE : RECEIVING MATERIAL QUALITY INSPECTION.

gg.

Thickness of extruded film. :

Unit : Micron. Purpose : To determine Thickness of film using Gaugemeter. Procedure : Film Sample is taken Its thickness at various points in lengthwise direction is checked with Gaugemeter & noted down. Now avarage of these thicknesses is determined which will give you avarage thickness of film. Formula : Avg. Thickness of Film = Sum of all thicknesses / no. of thickness points. hh.Pigmentation : Purpose : To verify that pigmentation of pigmented film is same as that of std. Film sample of same thickness. Procedure : Pigmented Film sample is taken. Its pigmentation is compared with standard pigmented Film sample of same thickness in light. After close observation its pigmentation level is determined. ii. Processing Defects of extruded film. :

Purpose : To check whether extruded film sample is free from all processing defects. Procedure : Extruded film sample is taken. This film sample is held in light & observed closely for any of the processing defects like gels, pinholes. Dielines, foldings etc. jj. Colour shade verification test. : Purpose : To compare colour shades of printed film with standard film sample. Procedure : Printed film sample is taken & compared with std. Film sample to check that colour shade of sample & standard film sample are matching. kk. Printing defects in printed film. :

Purpose : To check whether printed film sample is free from all printing defects. Procedure : Printed film sample is taken. It is compared with standard film sample in light to check printing defects like printing out, cylinder lines, colour lines, unwanted ink drops/ patches etc. ll. Scotch Tape Adhesion Test. : Purpose : to check adhesion of ink on poly film using cello tape. Procedure : Printed film sample / sample with dried drawdowm of ink is taken. Cello Tape is sticked on ink adhesion area & pressed. Now this cellotape is pulled rapidly & observed closely for any ink trace is removed or not. mm. Rub Test. : Purpose : To check that ink is not removed from polyfilm after rubbing it with tissue paper. Procedure : Printed film sample / sample with Drawdown of ink is taken. It is rubbed gently with tissue paper for one minute. Now it is checked whether ink is removed after rubbing or not.

nn.Slitted size of slitted film. : Unit : mm. Purpose : To determine slitted size of slitted film using scale. Procedure : Sliteed film sample is taken. Its size is measured with scale which will give slitted size of slitted film.

oo.

Core Inspection Test. :

Purpose : To inspect paper core used for winding of slitted film. Procedure : Visual testing of core is done to check quality of core used to wind slitted film. pp. Winding of Slitted Film. :

Purpose : To inspect winding of slitted film. Procedure : It is checked visually that winding of slitted film is proper. qq. Finishing of slitted Film. :

Purpose : To inspect finishing of slitted film. Procedure : Visual testing of slitted film is done to check whether slitting / cutting of film is proper or not & is free from trim.