CONCEPT OF INK KITCHEN IN CONVERTING INDUSTRIES Presenter: R. S. Prasad. Sakata Inx (India) Ltd Venue: PackAge Conference, Hall No.-8, Pragati Maidan, New Delhi Date /Time: 2nd December 2010 14:25 hrs to 14:50 hrs
Sakata Inx India Limited Introduction ØSakata Inx Corporation Japan (SIC) founded in Year 1896. Ranks 4 th in the turnover ranking with 1.2 b US $ revenue ØHas manufacturing bases in 16 countries with over 80 manufacturing sites including USA, Europe, Japan, China, Malaysia, Vietnam, Indonesia, Thailand, Philippines & India ØProduct range includes Solvent Based & Water Based Flexographic & Gravure Inks, News Ink, Offset Inks, UV Inks, Water Based & UV Varnishes, Metal Decorating Inks & Digital Inks & Toners. ØSakata Inx has R D centre s in Japan, USA and India to work on new technologies, raw materials and provide products required by the customers and also to meet the changing needs
Sakata Inx India Limited Introduction ØSakata India is 100% subsidiary of Sakata Inx Corp. Japan & established in Nov 1998 ØSakata India has two manufacturing facilities, Plant 1 at Bhiwadi & plant 2 at Panoli ( Gujarat) ØSakata India produce Gravure, Flexo and offset inks and is leading supplier to all key convertors with excellent performance on Low to high speed machines Ø Sakata India is ISO 9001: 2000, ISO 14001: 2004 & OHSAS 18001:1999 certified company (Certified by TUV Management Service GmBH ØKnown in Indian Market as a supplier of high performance, high productivity & consistent Inks, with high level of technical servicing & innovative approach to work closely with customers. ØHas been growing at a CAGR of 26% for the last three years, Current year we expect to repeat this performance.
Printing Printing is a process of reproducing text and image, typically with ink on substrate using a printing press. Ink is the carrier of the graphics and visuals intended to be printed on a substrate. Both combined together is VISUAL COMMUNICATION TECHNOLOGY
Flexible Packaging: Flexo Printing
Flexo Printing systems
Flexible Packaging: Gravure Printing
Gravure/Intaglio printing
Ink Kitchen On the basis of Ink application and the needs to manage inks, Sakata has been able to set the Ink Kitchen Systems for Gravure Printing at various locations. The Operational Excellence is well proven since over a decade now. And the demand to manage Ink Kitchen is growing
Ink Kitchen: Objectives 1. To understand ink and its application correctly and enhance operational efficiencies by minimising losses. 2. To utilise base colour concept (about 15 colours) to avoid high inventory of Fresh Inks in terms of all special colour shades of a job.
Ink Kitchen: Objectives 3. To provide consistent Press Ready Inks to the press to eliminate the struggle to get the desired colour shade on the press. 4. To maintain low inventory of Press Return inks below assigned limit by ensuring its reuse in different jobs. 5. To provide technical expertise in all aspects of converting operations including cylinder proofing, printing and post printing processes.
Understanding Ink and its Application Colourants / Pigments 5 30 % Binder systems 15 60 % Solvents 20 70 % Additives 1 10 %
Understanding Ink and its Application Color Strength (MT / UT) Hiding PowerLight Fastness Adhesive compatibility Gloss Resistance properties Flow Storage stability Shade Tinctorial strength Abrasion Blocking
Understanding Ink and its Application Lightfastness Rub oil Resistance properties Soap/Alkali Deep freeze Heat
Understanding Ink and its Application
Utilising Base Colour Concept 3% 7% 13% 25% 50% 75% 100%
Utilising Base Colour Concept Yellow Black Red Brown
Consistent Press Ready Ink
Control of Dilute Inks by Proper colour utilisation
Control of Dilute Inks by Proper colour utilisation
Technical Expertise: Understanding Colour Inks Pigments or Dyes Solvents Resin Process Parameters Analytical methods Instrumentation Calibration Substrates Type of Substrate Surface Energy Compatibility with ink Resistance Properties Storage Condition Dimensional Stability Laminates Ink / Adhesive compatibility Adhesive / Sealant compatibility Curing Condition Bond Strength Thermal Stability
Technical Expertise: Understanding Colour
Technical Expertise: Measurement of Colour
Technical Expertise: Understanding Gravure Cylinder
Technical Expertise: Understanding laminate Substrate Ink Adhesive Sealant
Testing Inks For Various applications Various tests can be listed as: For Reverse application Lamination grade: 1. Ink adhesion / Blocking 2. Ink GSM 3. Solvent retention 4. Odour 5. Required Lightfastness 6. AR/SR 7. Boil and Retort grade of Inks 8. Compatibility with various adhesive 9. Adequate Bond Strength 10. Compliance to food grade application
Testing Inks For Various applications For Surface application Non Lamination grade: 1. Ink adhesion / Blocking 2. Ink GSM 3. Solvent retention 4. Odour 5. Required Lightfastness 6. Product Resistance: Water, Milk, Ghee, Oil Detergent 7. Heat Resistance 8. Rub / Scuff Resistance 9. Deep freeze Resistance 10. Compliance to food grade applications etc.
Various Testing Rub Resistance Tester Fade-O-Meter
Various Testing Bond Strength Heat Gradient Tester
Ensuring compliance on Printing Inks Conformation to international standard: With world market merging together conformation to different international standards (CONEG, FDA, NL regulations of Japan, European Standard EN71/3) has become almost the basic requirement. These are basically to eliminate hazardous substance such as Cadmium and its Compounds, Cyanide Compounds, Organic phosphorous compounds, Lead and its compounds, Hexavalent Chromium Compounds, Arsenic and its compounds, Mercury and its compounds, PCB, Trichloroethylene and tetrachloroethylene.
Ink Kitchen On the basis of the operational excellence through Ink Management Systems Sakata has been able to consistently achieve deliverables that is directly resulting into benefits of the converters. These benefits can be outlined as:
Ink Kitchen: No wastage No wastage for shade matching on the machine due to variance in Ink colour shade. The first registered print is well within the approved LSD. Of course, we ensure no wastage of Ink due to wrong mixing.
Ink Kitchen: Minimum Shade matching Time To establish Stranger jobs, we provide our expertise of shade matching skill and assist in approval of the color shade. For Repeater jobs we ensure de below 2 so that no correction is required on the machine.
Ink Kitchen: Consistency of colour shade We provide total required quantity of ink in the press ready form so there is no deviation of colour shade throughout the print run if all other parameters are maintained. On the press we need to maintain the viscosity through out the print run to ensure the consistent print run.
Ink Kitchen: Minimum Dilute Ink Stock We utilise the press return inks of one job effectively by converting it for another job and thereby ensure minimum dilute ink stock.
Ink Kitchen: Prompt Services Press Ready inks are supplied to printing press within two hrs of the Ink requirement ensuring no machine waiting for inks.
Ink Kitchen: Prompt Services We at Ink Kitchen manages colour by managing Inks And Ink Management results not only in colour management but also adds to the productivity and reduction of various wastages
Emerging Technologies Sakata India has got the high performance ink systems and within a span of 12 years has been able to place itself as the main supplier of liquid printing ink. Sakata India enjoys the market share more than 35% in total and more than 80% in the quality segment. Sakata India has been able to strengthen itself in its assigned territory of SAARC Nations, Middle East, Africa and now strengthening itself in the erstwhile USSR region. Sakata India extends various analytical solutions to strengthen the flexible packaging market.
Emerging Technologies As a latest product Sakata India has launched the technology of High performance Polyurethane Base Toluene and MEK Free Ink System known as BELLECOLOR
THANKS!!!