Production Flow Chart

www.salmangroup.com























































1

Introduction:




Most of Salman group products are Custom made products.

Manufacturing process, are the steps through which raw materials are transformed
into a finished Goods.

The manufacturing process begins with the product design and material
specifications from which the product is made.

These materials are then modified through manufacturing processes to become the
required Products.

Modern manufacturing includes all intermediate processes required in the production
and integration of a product's components.

In this Manual we will find out the best way to produces custom mad products with
Lower cost, best quality and faster delivery time.


The Benefit of this manual:

1- Better utilization of group machine capacities.
2- Lower of Production cost.
3- Better competitive price.
4- Faster Delivery time.





























2

Table of Contents

Printing Methods …………………………………………………………………….. ………… ….… 5


Products Segments ………………………………………………………………………………………… 7
Flexible Packaging …………………………………………………………………………………………. 10


Mono Layer Wrap …………………………………………………………………………………………. 10

Beverage Label …………………………………………………………………………………….. 11

Laminates ………………………………………………………………………………………………… 12

Poly Bags ………………………………………………………………………………………………….. 2


Poly Sleeve ……………………………………………………………………………………………….. 2

Sugar Wrap ………………………………………………………………………………………………. 2

Paper Wrap……………………………………………………………………………………………… 3


Adhesive Label ………………………………………………………………………………………….. 4

Beverage Sticker ………………………………………………………………………………………. 2

Thermal Sticker ………………………………………………………………………………………… 2

Thermal Transfer Sticker ..……………………………………………………………………..…. 2


Fan Folded Sticker …………………………………………………………………………………….. 2

Safety Sticker ……………………………………………………………………………………………. 2


Burger Wrap ……………………………………………………………………………………………… 4

Foil Lids …………………………………………………………………………………………………….. 4

Blister Foil ……………………………………………………………………………………………………. 4

Casher Roll …………………………………………………………………………………………………… 4


Continuous Forms …………………………………………………………………………………….. 5









3

Printing Methods





Salman Group has different Types of printing Methods.


1- Offset Printing.


A- Sheet-Fed Offset.


 GTO Models : Al-Raja PP


Machine
Sheet Hrs Location # of OPV
Machine Size Substrate Speed Function Value Colors
mm GSM Sheet/Min
SR/Hr

Offset
GTO IV 50 x 35 50-300 3000 Al-Raja 2 Nill
Printing



 Speed Master Models: Al-Raja PP “2 Presses”

Machine # of
Sheet Size Substrate Speed Hrs Location Colors OPV
Machine Function Value
mm GSM Sheet/Min
SR/Hr
Speed Master 102 x 72 60-400 12000 Offset Al-Raja 4 Yes
CD102 Printing


 KBA Models : Noor Carton “2 Presses”

Machine # of
Sheet Size Substrate Speed Hrs Location Varnish
Machine Function Value Colors
mm GSM Sheet/Min
SR/Hr
KBA 102 x 72 Offset 5 / 6 Yes
Rapida 105 60-400 15000 Printing NOOR




4

B- Reel Fed Offset (Rotatek).


 Rotatek 200 : Al-Raja PP

Machine
Reel Hrs Location # of Die Cut
Substrate Speed Colors
Machine Width GSM Meter/Min Function Value
mm
SR/Hr
Offset
Rotatek RK200 102 x 72 60-400 12000 Al-Raja 4 No
Printing

 Rotatek 250 : FAFA

Machine
Reel Hrs Location # of Die Cut
Substrate Speed Colors
Machine Width GSM Meter/Min Function Value
mm
SR/Hr
Offset
Rotatek RK250 102 x 72 60-400 12000 FAFA 4 Yes
Printing


































5

Offset Printing Unit Offset Plate





















Rotary Offset “Rotatek RK Models” Sheet Fed Offset “Speed Master”



















Sheet Fed Offset KBA Rapida Model










6

2- Flexographic Printing (Cronoflex C.I, KYMC C.I, Aqua flex, Mark Andy).


A- C.I Flexo.


 Cronoflex Model : FAFA

Machine
Reel Substrate Hrs Location # of Other
Speed Colors Option
Machine Width Thickness Meter/Min Function Value
mm micron
SR/Hr
Nordmecanica 1215 20-200 300 Flexo FAFA 8 Nill
Cronoflex Printing

 Mark Andy Model : FAFA

Machine
Reel Substrate Hrs Location # of Other
Speed
Machine Width Thickness Meter/Min Function Value Colors Option
mm micron
SR/Hr
Flexo In-line
910 250 20-200 60 FAFA 4
Printing slitting

 KYMC Model : Noor Carton

Machine
Reel Substrate Hrs Location # of Other
Machine Width Thickness Speed Function Value Colors Option
mm micron Meter/Min
SR/Hr

1400 20-200 300 Flexo NOOR 6 In-line
Printing slitting



B- In Line Flexo.


 Aqua Flex Model : FAFA

Machine
Reel Substrate Hrs Location # of Other
Machine Width Thickness Speed Function Value Colors Option
mm micron Meter/Min
SR/Hr

520 20-200 150 Flexo FAFA 8 Die Cut /
Printing UV

7

Flexo Printing Unit Flexo Printing Plate





















KYMC C.I Flexo in Line Flexo “Aqua Flex”






















8

3- Screen Printing.


















Manual Screen Auto Screen



4- Digital Printing. Sheet Fed Digital Printing (Heidelberg).






















5- Out Door /Indoor Printing Plotter.



























9

Flexible Packaging Code F-1


Adhesive Label Code F-2


Foil Lids Code F-3

Burger wrap Code F-4


Blister Foil Code F-5


Cashier Roll Code F-6

Continuous Forms Code F-7


Folded Carton Code N-1


Paper Cup Code N-2


Paper Bag Code N-3
Corrugated Carton Code N-4


Books and Magazine Code R-1

Brochures and Booklets Code R-2


Calendars Code R-3


NCR Code R-4

Flayer And Promotion Code R-5


Tags Code R-6


Wedding Cards Code R-7

Stationary Code R-8


Indoors and Outdoors Media Code R-9







10

Flexible Packaging Code F-1






F-1-1 Monolayer Film:


1- Printed/Unprinted BOPP.

2- Printed/Unprinted PE.

3- Printed/Unprinted PVC.

4- Printed/Unprinted CPP.


Machine
Unprinted Printed
hrs. Location
Width Substrate Substrate Speed Mono Layer Mono Layer
Machine Function Value
mm Micron GSM M/Min BOPP/CPP/ BOPP/CPP/
SR/Hr PVC/PE PVC/PE
Flexo FAFA Process 1 1 Option
st
Cronoflex C.I 1200 20-150 40-100 250 Printing
Flexo NOOR Process 1 2 Option
nd
KYMC C.I 1400 20-200 40-300 250 Printing
st
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Process 1 Process 2 1 Option
nd
HCI 1000 1000 20-201 25-200 200 Slitting FAFA Process 1 Process 2 2 Option







NOOR C.I Schiavi





Printing Slitting





FAFA C.I HCI 1000












11

F-1-2 Beverage Label:


1- BOPP white Label Grade.
2- BOPP Transparent Label Grade.


Machine Printed
hrs. Location
Width Substrate Substrate Speed Mono
Machine Function Value
mm Micron GSM M/Min Layer BOPP
SR/Hr Label
st
1
Flexo FAFA Process 1
Cronoflex C.I 1200 20-150 40-100 250 Printing Option
nd
Flexo NOOR Process 1 2
KYMC C.I 1400 20-200 40-300 250 Printing Option
st
1
Process 2
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Option
nd
FAFA Process 2 2
HCI 1000 1000 20-201 25-200 200 Slitting Option






NOOR C.I Schiavi






Slitting
Printing




FAFA C.I HCI 1000






















12

F-1-3 Printed / Unprinted Laminates:


1- Ketchup Pouch 3 Layers in reel form.
2- Ketchup Pouch 4 Layers in reel form.
3- PET/PE for food pack.
4- BOPP Trans/BOPP Metz for Light food Pack.
5- Paper/PE/Foil for Candy wrap.

Machine
Hrs Location
Width Substrate Substrate Speed Printed Unprinted
Machine Function Value
mm Micron GSM M/Min Laminates Laminates
SR/Hr
1
st
Flexo FAFA Process 1 Option
Cronoflex C.I 1200 20-150 40-100 250 Printing
nd
Flexo NOOR Process 1 2
KYMC C.I 1400 20-200 40-300 250 Printing Option
FAFA Process 2 Process 1
Nordmeccanica 1200 20-200 40-300 250 Lamination
st
1
Process 3
Process 2
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Option
nd
2
FAFA Process 3 Process 2
HCI 1000 1000 20-201 25-200 200 Slitting Option








































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