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MATERI
Proses produksi flexible packaging Pre press Printing Extrusion dan Dry Lamination Metalizing Material untuk flexible packaging : printing/main substrate, Barrier dan heat sealing Material yang umum digunakan dan cara pembuatannya Cara menentukan spesifikasi flexible packaging Contoh-contoh komposisi material multi layer
GUDANG / EKSPEDISI
FILMLESS ENGRAVING
SLIDE + F/A
SCAN
COMPUTER
ANALOG
DIGITAL (PIXEL)
KOREKSI / MANIPULASI
CYLINDER ENGRAVER
CYLINDER (1-6)
CELL WALL
CYLINDER
+
+ + + + + + +
100 % Cells with Channels
+ + + + + + +
+ + +
+
+ + +
+
95 % Cells
+
50 % Cells 7 % Cells
+
+ + +
Media Transfer di Macintosh Optical 3.5 230 MB Optical 5.25 1.3 GB Opical 5.25 625 MB External Hardisk 2 GB Floppy Disk 3.5 1.4 MB
CATATAN
1. Barcode cukup disebutkan nomor barcode serta Code : EAN/UPC/ITF Magnification : 80% - 200% Clear Area Height : mm 2. Teks Mandarin, Arab, Jepang atau teks asing lainnya harus sbb : a. Software Free Hand, Illustrator, atau Corel Draw dilakukan convert to path b. Hindarkan software Quark X Press dan Page Maker 3. Resolusi Image sebaiknya 300 dpi (tidak terinterpolasi) Color : CMYK atau RGB Hindarkan Bitmap dan Indexed Color Format File : EPS, TIFF minimal JPEG Khusus PC compressed format : AJR 4. Media Transfer Format : MAC Macintosh DOS PC
PEMROSESAN GAMBAR
FILM LESS
COMPUTER AIDED DESIGN OPTICAL DISK KOREKSI/MODIFIKASI PENGATURAN LAYOUT PRINT OUT COMPUTER BLUE PRINT/CHROMALIN/ PROOF OFFSET REFLECTION COPY ELECTROMECHANICAL ENGRAVING CHROME PLATING POLISH/CLEANING PROOF CYLINDER CETAK
PEMROSESAN CYLINDER
BASE : f , CIRCUM BUBUT (Fe) PLATING Ni 1-2 m Cu 200 m POLISH/CLEANING
FILM
DESIGN KASAR ORIGINAL ARTWORK FINAL ARTWORK LAYOUT FILM/COLOR SEPARATION MOUNTING
TEKNIK-TEKNIK CETAK
LETTER PRESS
IMAGE CARRIER
PLATE CYL
INK ROLLERS
PAPER
IMPRESSION CYLINDER
OFFSET
DAMPENING SYSTEM INKING SYSTEM INK TRAY PLATE CYLINDER
WATER PAN
SABLON
SQUEEGE INK
STENCIL
FLEXOGRAFI
INK PAN
SUBSTRATE WEB
GRAVURE
PAPER/ FILM IMPRESSION CYLINDER
GRAVURE CYLINDER
DOCTOR BLADE
INK FOUNTAIN
MESIN GRAVURE
RUBBER PRESS DOCTOR BLADE
+
TINTA COOLING ROLL HEATER POSITION COMPENSATION ROLL
PAPER
UNWINDER
SCANNING HEAD
BAK TINTA
REWINDER
PROSES LAMINATING
Drying Process
Second Material
First Material
Combining Roller
Doctor Blade
Adhesive Coating Rewinder
TANDEM LAMINATOR PROCESS & PACKAGING MATERIALS & DESIGN FOR SPICES
SW1 E1 UW AC1 Device Film & Materials Property & Function Unwinder A Ony/print Good impact strenght Good toughness Good heat resistance AC 1 Adhesive AC2 Extruder 1 C LDPE Improving Adhesion Bonding Good strenght processability Sandwich Unwinder 1 B Alumunium foil Gas barrier Moisture proof Good stiffnes Shielding light Good display effect AC2 Adhesive Improving bonding strength Contents resistance Extruder2 C LDPE Good processability Good sealability Sandwich Unwinder2 D Rewinder Product SW2 RW E2
Rewind
Thyristor &
Calculate Power V & I Feed Back V&I Transformer
1. Material untuk printing / main subtrate 2. Material untuk barrier 3. Material untuk heat seal 4. Material untuk melekatkan material - material di atas termasuk adhesive
Untuk proses cetak diperlukan material dengan sifat - sifat : - Mudah menyerap / menerima tinta - Permukaan cukup halus dan rata - Tahan terhadap perlakuan pada mesin cetak
uap air, udara dan gas-gas lainnya Karena metal foil tidak transparan dan kaca tidak flexible untuk flexible packaging umumnya digunakan bahan plastik (polymer) Pengaruh uap air dan oksigen terhadap makanan :
- Potato Chips
melempem
- Makanan berlemak
bau tengik
4. Cold room
5. General room 6. Controlled lab 7. Laboratory oven
Dry Foods
PT/PE/CPP OPP/PE/CPP PET/PE/CPP KOP/PE/CPP PT/PE/AL/PE OPP/PE/AL/PE PET/AL/PE PT/PR/PAPER/PE/AL/PE MST/PE/PAPER/PE/AL/PE OPP/PE/PAPER/PE/AL/PE PET/PE/PAPER/PE/AL/PE OPP/PE/VM-PET/PE/CPP PT/CPP MST/CPP OPP/CPP PET/CPP ONY/CPP KOP/CPP KPET/CPP KONY/CPP OPP/VMCPP
Liquid Foods
KPT/PE OPP/PE PET/PE ONY/PE KONY/PE KPET/PE PT/PE/OPP/PE PET/VM-PET/PE *1 *2 *1 *2 OPP/KPT/PE OPP/EVAL/PE OPP/PET/PE PET/EVAL/PE ONY/PE KONY/PE KPET/PE KPT/PE OPP/PE OPP/KPT/PE PET/AL/PE OPP/PVDC/PE PET/PVDC/PE ONY/PE PET/PE ONY/CPP PET/CPP PET/ONY/CPP PET/AL/PE PET/AL/CPP PET/AL/ONY/PE PET/AL/ONY/CPP
Oil Foods
Sausage Hamburger
Retort Foods
PE means PE, EVA, ionomer resin, PE (20 m)/PE (20~50m), PE (20 m)/EVA(20~50 m) and PE (20 m) /ionomer resin (20~50m) VM means Aluminium metalized
1. JENIS ISI
ISI
1. K.L. YG BERISI UDARA 2. K.L. YG BERISI GAS N (GAS FLUSHED) 3. VAKUM 4. BOIL/REBUS 5. RETORT 6. DIBEKUKAN 7. ASEPTIK 8. DIBERI ZAT DEOXIDANT 9. BIASA
OPP/PP MZ/Al
Al ON/LLDPE OPP LLDPE Al Al.ON
1. PENGARUH CAHAYA-A1
2. PENGARUH OKSIGEN-PET 3. PENGARUH UAP AIR-OPP 4. AROMA MUDAH HILANG-A1 5. ISI BEREAKSI THD K.L.
2. MESIN PENGISI
DENGAN TANGAN MESIN PENGISI DENGAN MESIN 1.1. POWDER 1.2. CAIRAN PADAT -2.1. KECEPATAN TINGGI 2.2. KECEPATAN SEDANG 3.1. CUP SEALER SEDERHANA 3.2. CUP SEALER + VACUM FORMING
1. VERTIKAL
2. HORIZONTAL
3. CUP
PRODUCT
SKEMA VFFS
NOTE : * WIDTH = C + OVERLAP * CUTOFF = FS + TCL ** WIDTH = FSW + 2 x SSW ** CUTOFF LENGTH = FSL + TES
CIRCUMFERENCE (C)*
SKEMA HFFS
END PRODUCT
3.BERAT ISI
1. UKURAN KECIL ( < 50 g ) 2. UKURAN SEDANG ( 50 g - 500 g ) 3. UKURAN BESAR ( + 1 kg - 2 kg )
4. SHELF LIFE
1. KEMASAN TUNGGAL 2. ADA KEMASAN LUAR : - KEMASAN LUAR - KEMASAN LUAR KARTON K.L
5.0
4.0
3.0
2.0
1.0
10
20
DAYS
6.0
5.0 4.0
3.0
2.0 1.0
10
15
6. HARGA JUAL
1. MURAH 2. AGAK MAHAL 3. MAHAL
7. KEINGINAN KHUSUS
1. MUDAH DISOBEK 2. BISA DITUTUP KEMBALI 3. BISA BERDIRI
LLDPE
EVA EAA HDPE CPP OPP PET
High Strength PE
Low Temperature Sealant Hot Tack Moisture Barrier, Stiffness Moisture Barrier, Sealant Printing, Moisture Barrier Printing, Gas Barrier
Ny
Oriented Nylon
MATERIAL
KERTAS
GRADE
KETERANGAN
MUDAH DISOBEK
PENGGUNAAN
LAMINASI DGN PE, UNTUK KEMASAN YANG MUDAH DIBUKA MAKANAN, OBAT, DLL OBAT (PRESS THROUGH PACK), TUTUP MENTEGA OBAT DAN KEMASAN LAIN YG HARUS DIBUKA UNTUK PERMEN HAMPIR SEMUA KEMASAN MENGGUNAKAN LDPE ATAU LLDPE UNTUK HEAT SEAL. MDPE DAN HDPE JARANG DIGUNAKAN
LITHO HVS KRAFT COATED 2 ALUMINIUM FOIL SOFT TEMPER HARD TEMPER 3 4 5 CELLOPHANE PVC PE PT MSAT PLAIN COATED LDPE MDPE HDPE LLDPE
UMUMNYA DIBERI COATING MUDAH DISOBEK BISA DIPLINTIR (TWIST) FUNGSI UTAMA ADALAH UNTUK HEAT SEAL
CATATAN :
0 0000 X
= = = =
MATERIAL
NYLON
GRADE
ONY PVDC COATED PET PVDC COATED METALLIZED PLAIN FILM COATED CO-EXTRUDED PEARLIZED METALLIZED PLAIN METALLIZED
Heat Seal
X X X X X 0 0 0 X 000 000
KETERANGAN
TAHAN TERHADAP TUSUKAN BAIK SEKALI UNTUK PRINTING
PENGGUNAAN
TERUTAMA DIGUNAKAN UTK CAIRAN &VACUUM NON-ALUMINIUM FOIL UNTUK KEMASAN YANG DIJALANKAN PADA MESIN PACKAGING KECEPATAN TINGGI MATERIAL ALTERNATIF UNTUK PET
PET
OPP
DIBANDINGKAN DGN PET, OPP KURANG TAHAN TERHADAP PANAS DIBANDINGKAN DGN LLDPE, CPP LEBIH MUDAH DIPOTONG (PUTUS) DI MESIN DAN TITIK LELEH LEBIH TINGGI
CPP
10
COPOLYMER
EVA EVA
X X
0 0
0000 0000
COCOK UTK MESIN KECEPATAN TINGGI (MISALNYA UTK PERMEN PILLOW PACK), BISA TAHAN LEBIH DARI 120'C (UTK STERILISASI DGN CARA "RETORT") DIBANDINGKAN DGN PE, MATERIAL ALTERNATIF SIFAT HEAT SEAL LEBIH (LEBIH BAIK) DARIPADA BAIK PE
FIGURE 2-4
CAST FILM
ORIENTED FILM
FIGURE 1
One-Side Sealable
C2 C3 SEAL LAYER
OPP CORE C2 C3 SEAL LAYER
Extruder
Winder
Slitting
Packaging
Melt Extrusion
Finishing Section
Polypropylene Resins T Die Heater Roll Corona Treatment Section OPP Tenter PRODUCT
Extruder Oven
Extrusion
Winder
Winding
Slitting
Packaging
Finishing Section
Slurry Coagulation
Aging
Sulfide Dissolving
Finishing Section
Roll Product
Packaging
Slitting
Drying Resin, Plasticizer, Organic Solvent and Wax Base Cellulose Film
Humidity Control
Lacquer
Stainless steel
Idler roll Rubber ( or pinch ) roll Powered Carrier rolls Die Stainless steel nip ( or pinch ) roll ( driven )i 2 ( or more ) water cooled Highly polished chill roll Wind up ( Usually twin stasion )
PRODUK
FOXS INNER FOXS FRUIT&MINT 150 gr POLO SPEARMINT 5 PACK COFFEEMATE 450 gr ALUFOIL-NESTEA BAG 1000 gr ALUFOIL BAG FOXS FRUIT & MINT 150 x 3 gr ALUFOIL-FOX TROPICAL FRUIT 100gr POUCH MILO CM 750 gr SACHET CERELAC RICE & NESTUM RICE MAGGI NOODLE WRAP. SEASONING BEEF & CHICKEN MBI 50 gr. RICE FLAKE FOIL PORRIDGE NBI 50 gr METALIZING MAGGI
STRUKTUR MATERIAL
PET 12/PR/DL/VMCPP25 PET 12/PR/DL/AL 7/PE 18/LLDPE 25 PET 12/PR/DL/CPP 30 PET 12/PR/DL/AL 7/DL/LLDPE 45 PET 12/PR/PE 15/AL 7/P0E 25 PET 12/PR/PE 15/AL 7/PE 25 PET 12/PR/PE 15/AL 7/PE 25 PET 12/PR/PE 15/AL 7/PE 30 PET 12/PR/DL/AL 7/DL/LLDPE 55 OPP 20/PR/PE 18 OPP 20/PR/DL/VMCPP 25 OPP 20/PR/DL/VMCPP 25
13.