Production Flow Chart

www.salmangroup.com











Production Process Flow Chart



Manual





A Guide to the Manufacturing Production Process


























1

Introduction:




Most of Salman group products are Custom made.

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

Lamination Methods ……. ………………………………………………………………………………. 5


Slitting Methods …………...………………………………………………………………………………. 5

Die Cutting Methods ………..…………………………………………………………………….….… 5


Products Segments ………………………………………………………………………………………… 7

Flexible Packaging …………………………………………………………………………………………. 10

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

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


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

Poly Bags ………………………………………………………………………………………………….. 15

Sugar Wrap ……………………………………………………………………………………………….. 16

Poly Sleeve ………………………………………………………………………………………………. 17

Paper Reel Wrap ……………………………………………………………………………………… 18


Adhesive Label ………………………………………………………………………………………….. 20

Beverage Sticker ………………………………………………………………………………………. 23


Thermal Sticker ………………………………………………………………………………………… 25
Thermal Transfer Sticker ..……………………………………………………………………..…. 26


Fan Folded Sticker …………………………………………………………………………………….. 28

Safety Sticker ……………………………………………………………………………………………. 30


Burger Wrap ……………………………………………………………………………………………… 34

Foil Lids …………………………………………………………………………………………………….. 36

Blister Foil ……………………………………………………………………………………………………. 37


Casher Roll .…………………………………………………………………………………………………… 38

Continuous Forms .…………………………………………………………………………………….. 40



3

Folded Carton …..……………………………………………………………………………………….. 41

Cups & Bowl ….……..………………………………………………………………………………………. 44

Plastic/paper Lids …………………………………………………………………………………………. 46

Paper Bag ……………………………………………………………………………………………………… 47

Corrugated Carton ………………………………………………………………………………………… 47


Books and Magazine ………………………………………………………………………………….. 20

Brochure and Booklets ………………………………………………………………………………. 20

NCR ……………………….………………………………………………………………………………….. 20

Flayer And Promotion ……………………………………………………………………………….. 20

Tags ………………………………………………………………………………………………………….. 20

Wedding Cards ……….………………………………………………………………………………….. 20


Stationary ……………………..………………………………………………………………………….. 20

Indoor & Outdoor Media ……………………………………………………………………………….. 20




























4

Printing Methods




Salman Group has different Types of printing Methods.


1- Offset Printing.


A- Sheet-Fed Offset.


 Heidelberg GTO Models : Al-Raja PP


Machine
Sheet Hrs Location # of Other
Speed
Machine Size Substrate Sheet/Min Function Value Colors Options
GSM
mm
SR/Hr
Offset
GTO V/ IV 50 x 35 50-300 3000 Al-Raja 1 / 2 Nill
Printing



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

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

Speed Master 102 x 72 60-400 12000 Offset Al-Raja 4 OPV
CD102 Printing



 KBA Models : NCPI “2 Presses”

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





5

B- Reel Fed Offset (Rotatek).


 Rotatek 200 : Al-Raja PP

Machine # of Other

Reel Width Substrate Speed Hrs Location Colors Options
Machine Function Value
mm GSM Meter/Min
SR/Hr
Rotatek 500 60-400 12000 Offset Al-Raja 4 Fan Folding
RK200 Printing




 Rotatek 250 : FAFA

Machine # of Other
Reel Width Substrate Speed Hrs Location
Machine Function Value Colors Options
mm GSM Meter/Min
SR/Hr

Rotatek 500 Offset 4 Die Cut /
RK250 60-400 12000 Printing FAFA Fan Folding
































6

Offset Printing Unit Offset Plate





















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



















Sheet Fed Offset KBA Rapida Model










7

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 NCPI 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

8

Flexo Printing Unit Flexo Printing Plate

























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



















9

3- Screen Printing.


















Manual Screen Auto Screen



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






















5- Out Door /Indoor Printing Plotter.



























10

Lamination Methods




1- Solvent less Adhesive Lamination. FAFA

2- Hot melt Lamination. FAFA

3- Thermal Film/Paper Lamination. Al Raja PP

4- Cold Film/Paper Lamination. Al Raja


5- Corrugated Board flute Lamination. NCPI




Slitting Methods




1- Film Slitting. FAFA
2- Label Slitting. FAFA
2- Cashier Roll Slitting. FAFA
3- Board Slitting. NCPI





Die Cutting Methods



1- Flat Bed Die. Al Raja PP, NCPI
2- Flexible Die. FAFA

















11

PRODUCTS SEGMENTS



1. Flexible Packaging Code F-1


2. Adhesive Label Code F-2


3. Foil Lids Code F-3

4. Burger wrap Code F-4


5. Blister Foil Code F-5


6. Cashier Roll Code F-6

7. Continuous Forms Code F-7


8. Folded Carton Code N-1


9. Paper Cups & Bowl Code N-2

10. Paper & Plastic Lids Code N-3



11. Paper Bag Code N-4
12. Corrugated Carton Code N-5

13. Books and Magazine Code R-1


14. Brochures and Booklets Code R-2


15. Calendars Code R-3

16. NCR Code R-4


17. Flayer And Promotion Code R-5


18. Tags Code R-6

19. Wedding Cards Code R-7


20. Stationary Code R-8


21. Indoors and Outdoors Media Code R-9



12

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
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
st
Cronoflex C.I 1200 20-150 40-100 250 FAFA Process 1 1 Option
Printing
Flexo nd
KYMC C.I 1400 20-200 40-300 250 NCPI Process 1 2 Option
Printing
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Process 1 Process 2 1 Option
st
nd
HCI 1000 1000 20-201 25-200 200 Slitting FAFA Process 1 Process 2 2 Option








NCPI C.I Schiavi





Surface Printing Slitting
Printing





FAFA C.I HCI 1000









13

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
Flexo 1
Cronoflex C.I 1200 20-150 40-100 250 FAFA Process 1
Printing Option
nd
Flexo 2
KYMC C.I 1400 20-200 40-300 250 NCPI Process 1
Printing Option
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





Surface Printing Slitting
Printing




FAFA C.I HCI 1000






















14

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
st
Flexo 1
Cronoflex C.I 1200 20-150 40-100 250 FAFA Process 1
Printing Option
nd
Flexo 2
KYMC C.I 1400 20-200 40-300 250 NCPI Process 1
Printing Option
Nordmeccanica 1200 20-200 40-300 250 Lamination FAFA Process 2 Process 1

st
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Process 3 Process 2 1
Option
nd
HCI 1000 1000 20-201 25-200 200 Slitting FAFA Process 3 Process 2 2
Option








NCPI C.I Schiavi




Reverse Printing
Printing Lamination Slitting





FAFA C.I HCI 1000














15

F-1-4 Poly Bag:


Machine

Width Substrate Substrate Speed hrs.
Machine Speed Function Value Location Poly Bag
mm Micron GSM M/Min
Pcs/Min
SR/Hr
st
Flexo 1
Cronoflex C.I 1200 20-150 40-100 250 FAFA Process 1
Printing Option
Flexo 2
nd
KYMC C.I 1400 20-200 40-300 250 NCPI Process 1
Printing Option
st
Bag
Weijeen 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 Printed
hrs. Location
Width Substrate Substrate Speed Mono
Machine Function Value
mm Micron GSM M/Min Layer BOPP
SR/Hr Label
Flexo 1
st
Cronoflex C.I 1200 20-150 40-100 250 FAFA Process 1
Printing Option
nd
Flexo 2
KYMC C.I 1400 20-200 40-300 250 NCPI Process 1
Printing Option
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



16

F-1-6 Paper Reel Warp:

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

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





NCPI C.I



F-1-7 Po Slitting HCI 1000
Printing


FAFA C.I







F 1-7 Poly Sleeve Sheet “Clorox”:
Machine
Width Substrate Substrate Speed Speed Poly Sleeve
Machine Function Hrs Location
mm Micron GSM M/Min Pcs/Min Sheet
Value
Flexo 1
st
Cronoflex C.I 1200 20-150 40-100 250 FAFA Process 1
Printing Option
Flexo 2
nd
KYMC C.I 1400 20-200 40-300 250 NCPI Process 1
Printing Option
Laminati
Nordmeccanica 1200 20-200 40-300 250 FAFA Process 2
on
st
Schaivi Slitter 1200 20-200 25-200 200 Slitting FAFA Process 3 1
Option
Sleeve
Poly Sleeve 1000 20-200 75 FAFA Process 4
Making
Sheet
Sheet Cutting 800 50-200 25-200 60 FAFA Process 5
Cutting


NCPI C.I



Printing Lamination Slitting Poly Sleeve Sheet cut


FAFA C.I


17

2- Adhesive Labels Code F-2







F-2-1 Beverage Sticker


F-2-2 Thermal Sticker

F-2-3 Thermal Transfer Sticker


F-2-4 Fan Folded Sticker

F-2-5 Safety Sticker














































18