Manufacturing Process

www.salmangroup.com












Manufacturing Process Manual




A Guide to the Production Process flow



















Edited by: Hesham Elashrey

2020

Introduction:




Salman group is a group of companies produces custom made packaging,
publishing and advertising products.

The 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 explain the best way to produces custom made 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.























1

Table of Contents


Printing Methods ..………..…………………………………………………………………….……….… 4

Lamination Methods ……..…………………………………….……………………………………..… 10

U.V Coating Methods …………...………………………………………………..……….……….…… 12


Slitting Methods …………...…………………………………………………..…………….……………. 13
Die Cutting Methods ………..…………………………………………………………..………….…… 15


Sheet Cutting Methods ………….…………………………………………………………….….….… 17



Products Segments


Flexible Packaging ………………………….……………..….……………………………………………. 20

Mono Layer Wrap ……………………………………………………………………………………. 20

Beverage Label …………..…………………………………………………………………………….. 22


Laminates ………………………………………………………………………………………………… 23

Poly Bag ………………………………………………………………………………………………….. 25

Sugar Wrap ……………………………………………………………………………………………….. 25

Poly Sleeve ………………………………………………………………………………………………. 26

Paper Reel Wrap ……………………………………………………………………………………… 26


Adhesive Label ………………………………………………………………………………………….. 28


Beverage Sticker ………………………………………………………………………………………. 28

Thermal Sticker ………………………………………………………………………………………… 29

Thermal Transfer Sticker …...………………………………………………………….……..…. 30

Fan Folded Sticker ……………………………………………………………………………………. 30


Safety and security Sticker……………….………………………………………………………. 31

Foil Lids ……………….…………………………………………………………………………… 32


Plastic/paper Lids …………………………………………………………………………….. 33


2

Burger Wrap ……..………………………………………….…………………………………. 35


Blister Foil ………………………………………….……………………………………………. 36

Cashier Roll .……………………………………………………………………………………… 37


Continuous Forms ………………………..……….……………………………………….... 38


Paper board Folded Box ……………….………………………………………………….. 40

Paper Cups & Bowl .…………….………….………………………………….……………. 46


Paper Bag ………………………………………………….……………………………………… 49

Books and Magazine ……………………………………………………………………….. 54


Promotion ……………………………….………………………………………………………. 55

Diary And Calendars ……………………………………………………………………….. 57


NCR Book and Sets ……………….…………………………………………………………. 59

Stationary ………………………………………………………………………………………… 61


Digital .………………...………………………………………………………………………….. 63


Media ……………….………………..………………………………….……………………….. 63


Corrugated board Box ……..……………………………………………………………….. 65























3

Printing Methods




Salman Group has different Types of printing Methods.


1- Offset Printing.


A- Sheet-Fed Offset.


 Heidelberg GTO Models : Al-Raja PP

Machine
Mechanical # of Other
Sheet Size Substrate Hour Location Colors Options
Machine Speed Function Value
mm GSM
Sheet/Min
SR/Hr
Offset
GTO V/ IV 500 x 350 50-300 3000 Al-Raja 1 / 2 Nil
Printing


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

Machine
Mechanical # of Other
Sheet Size Substrate Hour Location
Machine Speed Function Value Colors Options
mm GSM
Sheet/Min
SR/Hr
Speed Master 1020 x 720 60-400 15000 Offset Al-Raja 4 OPV
CD102 Printing


 KBA Models : NCPI “2 Presses”

Machine
Mechanical Hour Location # of Other
Sheet Size Substrate
Machine Speed Function Value Colors Options
mm GSM
Sheet/Min
SR/Hr
KBA 1020 x 720 Offset 5 / 6 OPV
Rapida 105 60-400 20000 Printing NCPI







4

B- Reel Fed Offset (Rotatek).




 Rotatek 200 : Al-Raja PP

Machine
Reel Printing Mechanical Hour Location # of Other
Substrate Colors Options
Machine Width Width GSM Speed Function Value
mm mm Meter/Min
SR/Hr
Rotatek Offset
520 500 40-240 150 Al-Raja 4 Fan Folding
RK200 Printing



 Rotatek 250 : FAFA

Machine
Reel Printing Mechanical Hour Location # of Other
Machine Width Width Substrate Speed Function Value Colors Options
GSM
mm mm Meter/Min
SR/Hr
Rotatek 520 500 40-240 150 Offset FAFA 4 Die cut /
RK250 Printing Fan Folding






























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 Printing Mechanical Hour Location # of Other
Substrate Colors Options
Machine Width Width Thickness Speed Function Value
mm mm Meter/Min
SR/Hr
Nordmecanica Flexo
1225 1200 20-200 300 FAFA 8 Nil
Cronoflex Printing


 Mark Andy Model : FAFA
Machine
Reel Printing Mechanical Hour Location # of Other
Substrate Colors Options
Machine Width Width Thickness Speed Function Value
mm mm Meter/Min
SR/Hr
Flexo In-Line
Mark Andy 910 260 250 20-200 90 FAFA 4
Printing Slitting


 KYMC Model : NCPI
Machine
Reel Printing Mechanical Hour Location # of Other
Substrate Colors Options
Machine Width Width Thickness Speed Function Value
mm mm Meter/Min
SR/Hr
Flexo In-line
KYMC 1410 1390 20-200 300 NCPI 6
Printing slitting



B- In Line Flexo.

 Aqua Flex Model : FAFA

Machine
Reel Printing Mechanical Hour Location # of Other
Machine Width Width Substrate Speed Function Value Colors Options
Thickness
mm mm Meter/Min
SR/Hr
Flexo Die Cut /
LX 2058 520 500 20-200 150 FAFA 8
Printing UV




7

Flexo Printing Unit Flexo Printing Plate
























KYMC C.I Flexo In-Line Flexo “Aqua Flex”
















8

3- Screen Printing. AL-Raja PP






















Manual Screen Screen Printing Machine



4- Sheet Fed Digital Printing. AL-Raja PP


















Heidelberg Linoprint

5- Out Door /Indoor Printing Plotter. Al-Raja PP






















Plotter


9

Lamination Methods

Salman Group has different Types of Lamination Methods.


1- Solvent less Adhesive Lamination. FAFA

2- Wax Coating/Hot melt Lamination. FAFA


Machine
Reel Substrate Mechanical Hour Location Other Option
Machine Width Thickness Speed Function Value
mm micron Meter/Min
SR/Hr
SL
Nordmecanica 1220 20-200 300 Adhesive FAFA Wax
Combi wax Coating/Lamination
Lamination






















Malty Layer Adhesive Lamination































Wax Coating and Lamination


10

3- Thermal Film/Paper Lamination. Al Raja PP


Machine
Mechanical
Sheet Size Substrate Hour Location Other Option
Machine Speed Function Value
mm GSM
Sheet/Hr
SR/Hr
Thermal
Swafam 1050 100 x 70 100-400 1200 Al Raja PP Nil
Lamination






























4- Corrugated Board flute Lamination. NCPI

Machine
Mechanical Hour Location Other Option
Sheet Size Substrate
Machine Speed Function
mm GSM Value
Sheet/Hr
SR/Hr
Glue
Aspire 1450 x 1450 200-800 3000 NCPI Nil
Lamination






















Board / Micro Flute Lamination

11

U.V Coating Methods


Salman Group has different Types of U.V coating Methods.


1- Offline Coating .NCPI

U.V coating carried out by Blanket.


Machine
Mechanical Other
Sheet Size Substrate Hour Location
Machine Speed Function Substrate
mm GSM Value
Sheet/Hr
SR/Hr
U.V
Yiille Coating 1480x1070 60 -600 6000 NCPI Nill
Coating















U.V Coating Machine


2- Offline Coating. Al Raja PP


U.V coating carried out by Manual or Machine “Screen printing”.

Machine
Mechanical Other
Sheet Size Substrate Hour Location
Machine Speed Function Substrate
mm GSM Value
Sheet/Hr
SR/Hr
Jinbao U.V Screen
100x70 100 -300 500 Al Raja PP
Screen press Coating Printing



3- Inline Coating. FAFA


U.V Coating is carried out inline during printing by Aquaflex Machine.



12

Slitting Methods


Salman Group has different Types of Slitting Methods.


1- Film Slitting. FAFA

Machine
Reel Substrate Mechanical Hour Location Other
Machine Width Thickness Speed Function Substrate
Value
mm micron Meter/Min
SR/Hr
Paper /
Schiavi Slitter 1300 20-200 200 Slitting FAFA
laminates

























2- Label Slitting. FAFA

Machine
Reel Substrate Mechanical Other
Hour Location
Machine Width Thickness Speed Function Value Substrate
mm micron Meter/Min
SR/Hr
HCI 1300 Slitter 1300 20-200 200 Slitting FAFA Blister Foil





















13

2- Cashier Roll Slitting. FAFA


Machine
Reel Substrate Mechanical Hour Location Other Substrate
Machine Width Thickness Speed Function Value
mm GSM Meter/Min
SR/Hr

Lemu Slitter 1300 50 -200 150 Slitting FAFA Nil

























3- Board Slitting. NCPI

Machine
Reel Substrate Mechanical Hour Location Other Substrate
Machine Width Thickness Speed Function Value
mm GSM Meter/Min
SR/Hr

Nicely Slitter 1700 50 -750 200 Slitting NCPI Nil





























14

Die Cutting Methods


Salman Group has different Types of Die Cutting Methods.

























Flat Bed Die Cutter Rotary Die Cutter



-
- Flat Bed Die. Al Raja PP
























Auto feed Flat Bed Die cutting Manual Feed die Cutting







15

2- Flat Bed Die NCPI

Machine
Mechanical
Sheet Size Substrate Hour Location Other Option
Machine Speed Function Value
mm GSM
Sheet/Hr
SR/Hr
Glue
BOBST Expert 1060 x 760 100-800 3000 NCPI Nil
Lamination
































2- Rotary Flexible Die. FAFA


Rotary die cutting carried out in-line with Printing.


Two machine has Equipped with rotary die cutter in the group.

1- Aqua flex: FAFA

2- Rotatek RK 250: FAFA



















16

Sheet Cutting Methods


1- Board Sheet Cutting

Machine
Reel Substrate Mechanical Hour Location Other Substrate
Machine Width Thickness Speed Function Value
mm GSM Sheet/Min
SR/Hr
Sheet
GVA “GMC” 1800 50 -750 400 NCPI Nil
Cutting























2- Burger Wrap sheet Cutting.

A- High Speed Fully Automatic Sheet Cutting.
Machine
Reel Substrate Mechanical Hour Location Other Substrate
Machine Width Thickness Speed Function
Value
mm GSM Sheet/Min
SR/Hr
Sheet
Holweg Sheeter 1300 25 -200 150 FAFA Nil
Cutting























17

B- Conventional Sheet Cutting.

Machine
Reel Substrate Mechanical Hour Location Other Substrate
Machine Width Thickness Speed Function Value
mm GSM Sheet/Min
SR/Hr

Sheet
Weijin Sheeter 1300 25 -150 120 FAFA Plastic Film
Cutting



























3- Guillotine Machine.

Guillotine Machine is used to trimming and cutting stack of paper to desired size for
next production process.

























Polar Guillotine





18

PRODUCTS SEGMENTS



1. Flexible Packaging Code F-1

2. Adhesive Label Code F-2


3. Foil Lids Code F-3


4. Paper & Plastic Lids Code N-3

5. Burger wrap Code F-4


6. Blister Foil Code F-5


7. Cashier Roll Code F-6


8. Continuous Forms Code F-7

9. Paper Board Folded Box Code N-1


10. Paper Cup, Bucket and Bowl Code N-2


11. Paper Bag Code N-4
12. Books and Magazine Code R-1


13. Promotions Code R-2

14. Diary and Calendars Code R-3


15. NCR Books and Sets Code R-4


16. Stationary Code R-5

17. Digital Code R-6


18. Media Code R-7


19. Corrugated Board Box Code N-5











19

1- 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
Material Substrate Substrate Opt Hour Location Mono Layer Mono Layer
Machine Width Micron GSM Speed Function Value BOPP/CPP/ BOPP/CPP/
mm M/Min
SR/Hr PVC/PE PVC/PE

Cronoflex 1220 20-150 40-100 200 Flexo FAFA Process 1 1 Option
st
C.I Printing
Flexo
nd
KYMC C.I 1410 20-200 40-300 200 NCPI Process 1 2 Option
Printing
Schaivi 1200 20-200 25-200 150 Process 1 Process 2 1 Option
st
Slitter Slitting FAFA
nd
HCI 1000 1000 20-201 25-200 150 Slitting FAFA Process 1 Process 2 2 Option









NCPI C.I Schiavi



Surface Printing Slitting
Printing




FAFA C.I HCI 1000












20

Mono Layer PET Twist Wrapper Mono Layer CPP Bread Wrapper


































Mono Layer BOPP Wrapper Mono Layer PE Wrapper








21

F-1-2 Beverage Label:


1- BOPP white Label Grade.

2- BOPP Transparent Label Grade.

Machine Printed
Material Substrate .Substrate Opt Hour Location Mono
Machine Width Micron GSM Speed Function Value Layer BOPP
mm M/Min
SR/Hr Label

Flexo
st
Cronoflex C.I 1220 20-150 40-100 200 FAFA Process 1 1 Option
Printing
Flexo
nd
KYMC C.I 1410 20-200 40-300 200 NCPI Process 1 2 Option
Printing
st
Schaivi Slitter 1200 20-200 25-200 150 Slitting FAFA Process 2 1 Option
nd
HCI 1000 1000 20-201 25-200 150 Slitting FAFA Process 2 2 Option




NCPI C.I Schiavi



Printing
Surface Printing Slitting


FAFA C.I HCI 1000


































22

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
Material Substrate Substrate Opt Hour Location Printed Unprinted
Machine Width Micron GSM Speed Function Value Laminates Laminates
mm M/Min
SR/Hr
Flexo
st
Cronoflex C.I 1220 20-150 40-100 200 FAFA Process 1 1 Option
Printing
Flexo
nd
KYMC C.I 1410 20-200 40-300 200 NCPI Process 1 2 Option
Printing
Combi Wax 1200 20-200 40-300 200
Lamination Lamination FAFA Process 2 Process 1
st
Schaivi Slitter 1200 20-200 25-200 150 Slitting FAFA Process 3 Process 2 1 Option
nd
HCI 1000 1000 20-201 25-200 150 Slitting FAFA Process 3 Process 2 2 Option




NCPI C.I Schiavi


Reverse Printing
Printing Lamination Combi Slitting
Wax


FAFA C.I HCI 1000





Transparent PET film. Thickness: 12 µm
Ink. Thickness: 1 µm
Adhesive. Thickness: 2-4 µm
MET Foil Thickness: 7 µm
Adhesive. Thickness: 2-4 µm

Transparent PET film. Thickness: 12 µm
Adhesive. Thickness: 2-4 µm

Transparent PE film. Thickness: 40-130 µm.


23

4 Layer PET /Foil /PET /PE 3 Layer PET /PET Metz /PE




























2 Layer BOPP /BOPP Metz 2 Layer BOPP / CPP

























2 Layer PET / PE 2 Layer Foil /Paper






24

F-1-4 Poly Bag:


Machine
Material Substrate Substrate Opt Hour
Machine Width Speed Speed Function Value Location Poly Bag
mm Micron GSM M/Min Pcs/Min
SR/Hr
Flexo
st
Cronoflex C.I 1220 20-150 40-100 200 FAFA Process 1 1 Option
Printing
Flexo nd
KYMC C.I 1410 20-200 40-300 200 NCPI Process 1 2 Option
Printing
Bag
st
Wijien Bag 1200 40-200 60 Making FAFA Process 2 1 Option

NCPI C.I




Surface Printing Bag Making
Printing


FAFA C.I




F-1-5 Sugar Warp:


Machine
Material Substrate Substrate Opt Hour Location
Machine Width Speed Function Value Printed Mono
mm Micron GSM M/Min Layer BOPP Label
SR/Hr
Flexo
st
Cronoflex C.I 1220 20-150 40-100 250 FAFA Process 1 1 Option
Printing
Flexo
nd
KYMC C.I 1410 20-200 40-300 250 NCPI Process 1 2 Option
Printing
st
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Process 2 1 Option
nd
HCI 1000 1000 20-201 25-200 200 Slitting FAFA Process 2 2 Option



NCPI C.I Schiavi


Printing
Surface Printing Slitting

FAFA C.I HCI 1000



25

F-1-6 Paper Reel Warp:
Machine
Material Substrate Substrate Opt Hour Location Printed
Machine Width Speed Function Value Mono Layer
mm Micron GSM M/Min BOPP Label
SR/Hr
Flexo
st
Cronoflex C.I 1220 20-150 40-100 250 FAFA Process 1 1 Option
Printing
Flexo
KYMC C.I 1410 20-200 40-300 250 NCPI Process 1 2 Option
nd
Printing

HCI 1000 1000 20-201 25-200 200 Slitting FAFA Process 1




NCPI C.I




Printing
F-1-7 Po Surface Printing Slitting HCI 1000


FAFA C.I




F 1-7 Poly Sleeve Sheet “Clorox”:

Material Substrate Substrate Opt Speed Machine Poly
Machine Width Speed Function Hour Location Sleeve
mm Micron GSM M/Min Pcs/Min Value Sheet
Cronoflex 1220 20-150 40-100 200 Flexo FAFA Process 1 1 Option
st
C.I Printing
Flexo
nd
KYMC C.I 1410 20-200 40-300 200 NCPI Process 1 2 Option
Printing
Combi Wax 1200 20-200 40-300 200 Lamination FAFA Process 2
Lamination
Schaivi 1200 20-200 25-200 200 Slitting FAFA Process 3
Slitter
Sleeve
Poly Sleeve 1000 20-200 75 FAFA Process 4
Making
WeijinSheet 800 50-200 25-200 60 Sheet FAFA Process 5
Cutting Cutting


NCPI
C.I


Reverse Printing
Printing Lamination Slitting Poly Sleeve Sheet cut

FAFA
C.I


26

PE/PE Sleeve Poly Bag





























Paper Wrapper Paper/PE Sugar wrapper






27

2- Adhesive Labels Code F-2



F-2-1 Beverage Sticker


Machine
Material Opt
Machine Width Substrate Substrate Speed Function Location Hour Printing + Printing + BOPP
Micron GSM Value U.V Lamination
mm M/Min
SR/Hr
Aqua Flex 520 20-150 40-200 50 Printing FAFA Process 1 Process 1
st
HCI1300 1300 20-200 25-200 100 Slitting FAFA Process 2 Process 2 1 Option
Vinsak 600 40-200 100 Slitting FAFA Process 2 Process 2 2 Option
nd
Slitter


Aqua Flex Vensak




Printing Slitting



Rotatek HCI 1300
RK252














































28

F-2-2 Thermal Sticker “Scale Roll “

Machine
Material Opt Printing Printing
Substrate Substrate Hour
Machine Width Speed Function Up to 4 Up to 8
Micron GSM Location Value
mm M/Min Color Color
SR/Hr
st
Aqua Flex 520 20-150 40-200 75 Printing FAFA Process 1 Process 1 1 Option
Rotatek nd
500 40-240 75 Printing FAFA Process 1 2 Option
RK 250
st
HCI1300 1300 20-200 25-200 100 Slitting FAFA Process 2 Process 2 1 Option
Vinsak 600 40-200 100 Slitting FAFA Process 2 Process 2 2 Option
nd
Slitter



Aqua Flex Vinsak




Printing Slitting



Rotatek HCI 1300
RK252












































29

F-2-3 Thermal Transfer Sticker “Barcode Sticker”


Machine
Material Opt
Machine Width Substrate Substrate Speed Function Hour Location Printed
Micron GSM Value /Unprinted
mm M/Min
SR/Hr
st
Aqua Flex 520 20-150 40-200 75 Printing FAFA Process 1 1 Option
Rotatek nd
500 40-240 75 Printing FAFA Process 1 2 Option
RK 250
st
HCI1300 1300 20-200 25-200 100 Slitting FAFA Process 2 1 Option
Vinsak 600 40-200 100 Slitting FAFA Process 2 2 Option
nd
Slitter




Aqua Flex Vinsak



Printing Slitting




Rotatek HCI 1300
RK250




F-2-4 Fan Folded Sticker Label “continuous form”

Machine
Material Opt Hour
Substrate Substrate Printed
Machine Width Micron GSM Speed Function Value Location /Unprinted
mm M/Min SR/Hr

Rotatek 500 40-240 75 Printing FAFA Process 1
RK 250



Printing Rotatek Packing
RK250























30

F-2-5 Safety, Tamper evident, Security Sticker

Machine
Material Opt Hour
Machine Width Substrate Substrate Speed Function Value Location Printing Up Printing Up to
Micron
to 4 Color
8 Color
GSM
mm M/Min SR/Hr

st
Aqua Flex 520 20-150 40-200 75 Printing FAFA Process 1 Process 1 1 Option
Rotatek 500 40-240 75 Printing FAFA Process 1 2 Option
nd
RK 250
st
HCI1300 1300 20-200 25-200 100 Slitting FAFA Process 2 Process 2 1 Option
Vinsak nd
600 40-200 100 Slitting FAFA Process 2 Process 2 2 Option
Slitter





Aqua Flex Vinsak




Printing Slitting



Rotatek HCI 1300
RK250






































31

3. Foil Lids Code F-3



Machine
Material Substrate Substrate Opt Speed Hour Printed
Machine Width Function Value Location
mm Micron GSM M/Min Foil Lids
SR/Hr
Cronoflex C.I 1220 20-150 40-100 150 Printing FAFA Process 1 1 st Option

KYMC C.I 1410 20-200 40-300 150 Printing FAFA Process 1 2 nd Option
HCI1300 1300 20-202 25-200 100 Slitting FAFA

Bulldog foil
330 40 40 Lids Foil FAFA
lids




NCPI C.I


Lids
Printing Slitting HCI 1300 Punching



FAFA C.I
Bulldog
Lids Punch



Available Lid Sizes:


1- 73 mm
2- 75 mm
3- 95 mm
4- 104 mm
























32

4-Paper & Plastic Lids Code N-3



1- Paper Lids.

Sheet Substrate Opt Speed Machine Paper/Plastic
Machine Size Speed Function Hour Location
GSM Sheet/Hr Cup/Bowl
mm M/Min Value
KBA Sheet 1020 40-300 1200 Flexo
fed Offset x720 Printing NCPI Process 1
BOBST 1020 12000 Sheet
Die cutting x720 cutting NCPI Process 2
Cup
Cup Making 800 25-200 60 NCPI Process 3
making







Printing Rapida 105 Die Cut BOBST Expert Lids Making









































33

2- Plastic Lids.

There are different sizes and types of plastic lids.

Machine # Size Lid/Hour Lid Type

# 1
# 2
# 3
# 4


A- Types of Plastic lids.

1- PP.
2- PET.
3- PS.

B- Sizes of Plastic lids.

1- 8 Oz
2- 9 Oz
3- 12 Oz
4- 16 Oz





































34

5. Burger wrap Code F-4


F-4-1 Paper Wax

Machine
Material Opt
Substrate Substrate Speed Hour Paper
Machine Width Speed Function Location
Micron GSM Pcs/Min Value Wax
mm M/Min SR/Hr
Flexo
Cronoflex C.I 1220 20-150 40-100 250 FAFA Process 1 1 Option
st
Printing
Flexo
nd
KYMC C.I 1410 20-200 40-300 250 NCPI Process 1 2 Option
Printing
Combi Wax 1200 20-200 40-300 250 Lamination FAFA Process 2
Lamination
Hollweg 1200 25-200 150 Sheet
Sheet Cutting 400 Cutting FAFA Process 3


NCPI C.I
Combi

Printing Wax Coating Wax Sheet Cutting


FAFA C.I

Hollweg
Sheeter


F-4-2 Paper / Foil “Mono component/Spot Lamination”

Machine
Opt
Width Substrate Substrate Speed Hour
Machine Speed Function Location Paper /Foil
mm Micron GSM Pcs/Min Value
M/Min
SR/Hr
Combi Wax 1200 20-200 40-300 200 Process 1
Lamination Lamination FAFA
Flexo
Cronoflex C.I 1220 20-150 40-100 200 FAFA Process 2
Printing
Hollweg Sheet 1200 25-200 150 Sheet Process 3
Cutting 400 Cutting FAFA


Combi FAFA Sheet Hollweg

Lamination Printing
Wax C.I Cutting Sheeter



















35

6. Blister Foil Code F-5



Machine
Opt Hour
Width Substrate Substrate Printing Up to
Machine Speed Function Value Location
mm Micron GSM SR/Hr 8 Color
M/Min

Flexo st
Aqua Flex 520 20-150 40-200 75 FAFA Process 1 1 Option
Printing
Flexo nd
Cronoflex C.I 1220 20-150 40-100 100 FAFA Process 1 2 Option
Printing
st
HCI1300 1300 20-200 25-200 100 Slitting FAFA Process 2 1 Option



Aqua Flex



Printing Slitting HCI 1300



FAFA C.I














































36

7. Cashier Roll Code F-6



1- Unprinted

Machine
Opt
Width Substrate Hour Value Unprinted
Machine Speed Function Location
mm GSM SR/Hr Cashier roll
M/Min

st
Lemu Slitter 1300 25-200 100 Slitting FAFA Process 1 1 Option


2- Printed


Machine
Material Opt Hour Two Side Two Side One side
Machine Width Substrate Speed Function Value Location Printing Up Printing Up Printing Up
GSM
mm M/Min SR/Hr to 4 Color to 8 Color to 8 Color

Cronoflex st
1220 40-200 150 Printing FAFA Process 1 1 Option
C.I
nd
2 Option
KYMC C.I 1410 40-300 150 Printing NCPI Process 1 Process 1 Process 1
Rotatek 500 40-240 75 Printing FAFA Process 1A 2 Option
nd
RK 250
Rotatek 500 40-240 75 Printing FAFA Process 1B 2 Option
nd
RK 250
Lemu
1300 25-200 100 Slitting FAFA Process 2 Process 2 Process 2
Slitter




NCPI C.I



Printing FAFA C.I Slitting Lemu Slitter





Rotatek
RK250























37

8. Continuous Forms Code F-7


Continuous forms commonly used for

 Invoices
 Credit Notes

 Statements
 Remittance Advice

 Delivery Notes
 Order Forms
 Process Management


They can be 1, 2, 3 or 4 pages that have sprocket holes down the sides to
enable it to be fed through a dot matrix printer.
Printing on these types of continuous documents require a degree of impact to
ensure good transfer of type information from one sheet to the next.
The top sheet usually goes with the products, as this has the direct printed
copy.


Generally, the printer that is used for this will be left set up with the
continuous stationery in place all the time.

PERFORATIONS

Each copy can have perforations at the end of each set to make it easy to

separate as well as perforations along the edges, enabling you to remove the
sprocket holes. The micro perforations used make for a clean separation,
leaving you with clean edges.

Common sizes:

241mm x 216mm (9.5in x 8.5in).Al Raja PP
241mm x 279mm (9.5in x 11in). FAFA, AL Raja PP

241mm x 305mm (9.5in x 12in). FAFA

NCR (NO CARBON REQUIRED)

NCR was created to allow continuous NCR forms to be run through dot matrix
printers speeding up the process.


Process of making Continuous Forms Can be made by FAFA and Al-Raja PP.



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There are two Types of Continuous NCR forms

1- Variable printed codes w/out Back Print up to 4 colors. FAFA

Sizes: 11 and 12 in
Machine
Material Opt Opt Hour
Substrate Printing Up
Machine Width GSM Speed Speed Function Value Location to 4 Color
mm M/Min Sheet/Hr SR/Hr

Rotatek
500 40-240 75 Printing FAFA Process 1
RK 250
BAMA 40-200 7500 Collecting Al Raja PP Process 2
Collator 378


Al Raja PP
BAMA
Printing RK 250 Collator Collator



2- Printed up to 4 Colors. Al Raja PP

Sizes: 8.5 and 11 in
Machine
Material Opt Opt Hour
Substrate Printing Up
Machine Width GSM Speed Speed Function Value Location to 4 Color
mm M/Min Sheet/Hr SR/Hr

Rotatek 500 40-240 75 Printing Al Raja PP Process 1
RK 200
BAMA Process 2
Collator 378 40-200 7500 Collecting Al Raja PP


Al Raja PP
BAMA
Printing RK 200 Collator Collator






















Collator

39

9. Paper Board Folded Box Code N-1

The folded carton is a type of the packaging industry where it produces a
package made of paper board.

The process involves folding carton made of paperboard range from 200 up to
600 GSM that is printed, laminated, cut, then folded and glued.
The cartons either shipped flat to a packager, which has its own machinery to
fold the carton into its final shape as a container for a product.
An example of such a carton is a cereal box.
Or the folded carton glued to the required shape, keeping one or two sides
open for filling in automatic line.
An example of such a carton is a detergent box.


Some styles of folding cartons can be made of E-flute or micro-flute corrugated
fiberboard.































Examples of Folded Carton shapes
















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1- Straight Tuck Box (ST). 2- Reverse Tuck Box (RT)


























3- Crash Bottom Box (CB) 4- Lock Bottom Box (LB)



























5- One-piece Tuck Top Box (TT) 6- Two-Piece Box (TP)

























7- Holster Box (HOL) 8- Sleeve Pack (SE)

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9- Counter Display Box 10- Boxes with Custom Cutouts
























11- Snack and Food Boxes.

































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Shaping process of folded carton started from the die cutting process, in which
creasing perforation in window shape carried out.
The final processes of shaping carried out automatically inline or offline by ,

1- 4, 6 corner Folder Gluing machine.

2- Window batch machine.
3- Erecting machine.






















Folded Boxes Folder Gluer machine


















Window Patch Window Patch Making Machine
























Erecting Machine


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1- Boxes with 4, 6 corners end seal without window.

Opt Speed Machine
Sheet Size Substrate Paper Board
Machine Speed Sheet/Pcs Function Hour Location
mm GSM Box
M/Min Hr Value
KBA Rapida 1020 x720 60-700 12000 Offset NCPI Process 1
105 Printing
BOBST 1070 x760 60-700 7000 Sheet Process 2
Die cutting cutting NCPI
BOBST 100-700 10000- Folder Process 3
Omega 15000 Gluer NCPI



BOBST

Printing Rapida 105 Die Cut BOBST Folder Omega
Expert
Gluer
pert



2- Boxes with 4,6 corners with window .

Opt Speed Machine
Sheet Size Substrate Paper Board
Machine Speed Sheet/Pcs Function Hour Location
mm GSM Box
M/Min Hr Value
KBA Rapida 1020 x720 60-700 12000 Offset NCPI Process 1
105 Printing
BOBST 1070 x760 60-700 7000 Sheet Process 2
Die cutting cutting NCPI
Window 60-700 6000- Window NCPI Process 3
Patch 12000 Batch
BOBST 100-700 10000- Folder Process 4
Omega 15000 Gluer NCPI





Rapida BOBST Window BOBST
Printing Die Cut
105 Expert Patch Expert





BOBST Folder

Omega Gluer
pert






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C- Snack and Food Box.

Opt Speed Machine
Sheet Size Substrate Paper Board
Machine Speed Sheet/Pcs Function Hour Location
mm GSM Box
M/Min Hr Value
KBA Rapida 1020 x720 60-700 12000 Offset NCPI Process 1
105 Printing
BOBST 1070 x760 60-700 7000 Sheet Process 2
Die cutting cutting NCPI
Window 60-700 6000- Window NCPI Process 3 Optional
Patch 12000 Batch
Erecting 2/4 200-700 10000- Folder NCPI Process 3
liter 15000 Gluer






Rapida BOBST Window

Printing 105 Die Cut Expert Making




Erecting Window
Omega Patch



























45

10. Paper Cup, Bucket and Bowl Code N-2



Paper Cups and Bowls can be printed and die cut by two different methods.

Many factors effect on the Decision of way of printing and die cutting.


1- Design and required quality of printing.

2- Order quantity.

3- Competitive price.


In my opinion, if the order quantity is large, so the best way is to use flexo
printing in reel form the use reel fed die cutter.

If the order quantity is small or requires high printing quality, we should go for

sheet fed offset printing and sheet fed die cutting.

As shown below..




1- Large order quantity up to 8 colors.

Material Max Opt Speed Machine
Substrate Paper
Machine Width Sheet Speed Sheet/ Function Hour Location
GSM Cup/Bowl
mm Size mm M/Min Cup Hr Value
KYMC Flexo 1400 40-300 200 Flexo NCPI Process 1
C.I Printing
Dayuan Reel 1400 100-500 200 Reel Die NCPI Process 2 1 Option
st
Punching cutting
GVA 1600 60-500 10000 Sheet nd
Sheeter cutting NCPI Process 2A 2 Option
BOBST 1000 1060x760 60-500 7000 Sheet 2 Option
nd
Die cutting cutting NCPI Process 2B
Cup Making 100-350 4000 Cup NCPI Process 3
making



Sheet

Cutting
Reel Punching



Printing NCPI C.I Die Cut Cup Making




Sheet Cutting BOBST




46

2- Small order quantity and/or high quality print.

Opt Speed Machine
Sheet Size Substrate Paper
Machine Speed Sheet/Cup Function Hour Location
mm GSM Cup/Bowl
M/Min Hr Value
KBA Rapida 1020 x720 60-500 12000 Offset Process 1
105 Printing NCPI
BOBST 1070 x760 60-500 7000 Sheet Process 2
Die cutting cutting NCPI
Cup
Cup Making 100-350 4000 NCPI Process 3
making




Printing Rapida 105 Die Cut BOBST Cup Making
Expert


3- Double Wall Cups.


Material Max Opt Speed Machine
Substrate Paper
Machine Width Sheet GSM Speed Sheet/ Function Hour Location Cup/Bowl
mm Size mm M/Min Cup/Hr Value
KBA Rapida 1020 x720 60-500 12000 Offset NCPI Process 1
105 Printing
Dayuan Reel 1400 100-500 200 Reel Die NCPI Process 1 A 1 Option
st
Punching cutting
GVA 1600 60-500 10000 Sheet 2 Option
nd
Sheeter cutting NCPI Process 2A
BOBST 1060x760 60-500 7000 Sheet 2 Option
nd
Die cutting cutting NCPI Process 2B
Cup Making 100-350 4000 Cup NCPI Process 3
making



Sheet

Cutting Unprinted Reel Reel Punching




Printing Rapida 105 Die Cut Cup Making



Sheet Cutting BOBST









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 Available Reel Punching Cup Sizes.



1- 9 Oz inner & Outer
2- 12 Oz inner & Outer
3- 16 Oz inner & Outer


 Available Cups, Buckets and Bowls Sizes.


1- Cups: 8, 9, 12, 16 Oz
2- Bowls: 130, 160, 170 Oz

















































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11. Paper Bag Code N-4


Types of Paper Bags in Salman Group.

1- Satchel Bag “V Bottom Bag”. NCPI
2- S.O.S Bag. NCPI
3- Bakery Bag. NCPI
4- Handle Shopping Bag “Twisted, Flat Handle”. NCPI
5- Gift Bag “over 100 GSM”. Al Raja PP


Size of Paper Bag can be measured as figures.



























Satchel Bag “ V Shaped” Handle Shopping Bag























Bakery Satchel with window Bag Bakery Bag





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