How Gravure coating can eliminate „MUDA“ waste

How Gravure coating can
eliminate „MUDA“ waste

Fabian Umbach
6.4 / 7722

What is MUDA

• Muda is the Japanese word for waste.

• Wastes are costs / activities which are not increasing
the value of the product

• WHY ?????

• Customers are not paying for the additional work.

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What is MUDA $$$$

• 8 Waste categories:

1. Overproduction Æ long setup Æ low flexibility
2. Waiting Æ long setup
3. Unnecessary transport
4. Over processing or incorrect processing Æ Right equipment ?
5. Excess inventory Æ log setup Æ low flexibility
6. Unnecessary movement
7. Defects Æ Right equipment ?
8. Unused employee creativity Æ continues improvement

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Cost of the product

Production cost w/o labor Market and process related
Process related
Raw Material Process and operator related
Energy
Machine efficiency Process and operator related
Material waste

Process investment Process related

Initial Investment for new
equipment

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Example of interactions

Material waste Energy

Machine efficiency Process is not Initial Investment for new
ideal equipment

Production cost w/o labor goes up and you will lose profit

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What is Gravure / Smooth Roll Coating

• Gravure or smooth roll coating applies the coating
liquid with a roll to the substrate.

• In case of Gravure coating you have a chrome or
ceramic roll which is mechanically or laser engraved
cells. With the size of the cells the coat weight is
determined. It can be varied by using a Pressurized
Gravure Head “PGH” for higher speeds and ctw.

• In case of smooth roll coating the liquid get transferred
from a open pan with a smooth chrome roll and gets
applied to the web by contact with the

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Gravure Engraved Patterns

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CHECKING
NIP IMPRESSIONS = FOOTPRINT

RUBBER
COVERED
ROLL

FOOTPRINT

LOAD

STEEL ROLL 8

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COATER/DRYER set-up 9

Coater

Smooth roll

Backing Roll not Undercut

Pan Fed

Direct Gravure

Backing Roll Undercut
Sleeve

Pan Fed
Enclosed Applicator
Pressurized Gravure Head

Dryer

Air Floatation Nozzles
Roll Support

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FLEX-PACK COATERS

Direct Reverse Offset Smooth
Gravure Gravure Gravure Roll

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Gravure Coater Smooth Roll Coater

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Gravure Coater with “PGH”
Pressurized Gravure Head

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DIRECT GRAVURE

BACKING; LINESPEED
Undercut Required
BACKING/GRAVURE = 8-12mm NIP
GRAVURE; 90% to 110% LINESPEED

SOMETIMES REQUIRES POST SMOOTHING

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REVERSE GRAVURE

BACKING; LINESPEED
Undercut required

BACKING/GRAVURE = 8-12mm NIP

GRAVURE; 50% to 150% OF LINESPEED

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OFFSET GRAVURE

BACKING; LINESPEED

BACKING/OFFSET =8-12mm NIP

OFFSET; 95% to 105% OF LINESPEED
Undercut Required

OFFSET/GRAVURE = 8-12mm NIP

GRAVURE; 10% to 25% OF LINESPEED

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SMOOTH ROLL

BACKING; LINESPEED
NO Undercut Required
BACKING/PICKUP = VARY NIP
PICKUP;20% to 150% LINESPEED

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PRESSURIZED REVERSE GARVURE

BACKING; LINESPEED
Undercut required

NO AIR ENTRAPMENT AT HIGH SPEED

BACKING/GRAVURE = 8-12mm NIP

GRAVURE; 50% to 150% OF LINESPEED

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Series 4000
Cartridge Coating Station

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Typical Products

Product Package Type Interm. Product

• Processed Meat • Pouches, Vacuum • Primer Coated Film
• Top Coated Film
• Processed Cheese Packages • Silicon Film
• Adhesive coated Film
• Fresh Red Meat • Pouches, Wraps

• Bulk Liquids • Barrier, Shrink Bags

• Cereal/Cake Mix
• Medical Devices Films • Pouches, Bag in Box

• Coffee • Inner Liners

• Fresh Produce • Pouches, Thermal Formed

• Snacks • Brick Packs, Pouches

• Breathable Bags

• Bags

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Flex-Pack Components

Substrates Coatings

• PET 1-10 µ • Primers 0.04-0.4 gsm
• PE 1-8 µ
• Al foil 20-60 µ • Adhesives 3.25-6.5 gsm
• BOPP/OPP
• CPP 0.4-2 µ • PVDC 1.6-6.5 gsm
• Nylon 1-4 µ
• METPET • Wash-coats 0.8-1.5 gsm
• Cellophane 0.4-2 µ
1-10 µ • PVOH 0.5 gsm
0.8-1 µ
• Lacquer 5.0 gsm

• Acrylic Polyurethane 0.3 gsm

• Varnish 0.02 – 0.04 gsm

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Typical Product Structures

PET 12.6µ PET 12.6µ
(PRINT)
Tie layer 6µ E (PRINT) L
FOIL 6.3µ X ADHESIVE 3.25 – 5.5µ C
PRIMER 0.04µ
LDPE 25 µ L FOIL 6.3µ L
C PRIMER 0.04µ C

LDPE 25 µ

Retort Package Retort Package

Material Cost for EX Tie layer Æ 5 Euro/kg vs. Adhesive 3Euro/kg

Less coat weight in LC process.

Investment difference 1 compl. extruder; laminator ….. vs. Coater Dryer
station

High flexibility with coating stationÆ primer and adhesive coating

No process problems with Tie layer

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Typical Product Structures

LDPE 12.6µ LDPE 12.6µ

Board Board

LDPE 12.6µ E LDPE 12.6µ L
C
Tie layer 6µ X PRIMER 0.04µ
L
FOIL 6.3µ E FOIL 6.3µ C

Tie layer 6µ X PRIMER 0.04µ

LDPE (Heat Seal) 25µ LDPE (Heat Seal) 25µ

Beverage Package Beverage Package

Material Cost for EX Tie layer vs. Primer and less coat weight Investment

High Flexibility with coating stationÆ primer and adhesive coating

No process problems with Tie layer

Less heat problems due to lower extrusion weight Æ higher speeds

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Conclusions Which MUDA

• LC can reduce material cost Æ Over Processing
• LC can reduce initial investment
• LC can increase flexibility Æ Over Processing

• LC can reduce Tie layer problems Æ Overproduction
Æ Excess Inventory

Æ Defects

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Thank you

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