by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
FLEXO Magazine : October 2010
Technologies & Techniques Bobst Group North America, Inc. 13325 South Point Blvd, Suite 400, Charlotte NC 28273 Tel: 704 587 2450 Apparently we’re not the only ones who think smartGPS is a big deal. The smartGPS is our exclusive Graphic Positioning System which automatically generates registration and impression settings offline during plate mounting. This eliminates almost all set-up waste, providing stunning print quality starting with the first impression. n Automated set-up saves substrate, ink, energy, press time, labor and more. n Achieves perfect impression and register from the very first repeat. n Increased efficiencies open new markets to flexo printing. n Available on all Fischer & Krecke flexo presses. F&K FTA Award_Layout 1 5/27/10 7:18 AM Page 1 three-dimensional mock-up of the finished product before any production costs are incurred. The basic folding carton begins as a simple, two-dimen- sional, four-sided tube with an extension at one end, the glue flap, which allows the tube to be folded into its three-dimen- sional shape. Various types of closures, such as tuck tops and dust flaps (as seen in Figure 4) may be added on the top and bottom of the tube to create the final design. Layout If you look back at Figure 3, at the bottom left of the photo- graph you will see the large rolls of paperboard, which are the end result of the papermaking process. The paperboard mill slits these very wide rolls into smaller ones that will fit on the converter’s equipment. Cartons are not made one at a time, but rather in large sheets or in a continuous stream called a web. Whether printing will be accomplished on a web-fed or sheetfed press, the individual carton must be laid out in a pattern that attains the best use of board and the least amount of waste. This raw material may easily account for 35 percent or more of the total cost of the carton, so ef- ficient utilization is critical. Figure 5 shows a press sheet that will print two cartons. Die Making In the modern folding carton plant, the same computer program that generates the structure of the box and the sub- sequent production layout is used by the die maker to create a steel rule die. Many die boards today are cut by laser, insuring a much higher degree of accuracy and consistency between dies. Steel rule knives are then bent and cut to the required shape and fit into the slots burned by the laser. Where the de- sign calls for a crease, the steel rule has a rounded edge that creates a score around which the carton will fold. Also, note the “nesting” of cartons in Figure 5. Wherever possible, the boxmaker will maximize sheet utilization, creat- ing as little waste as possible. Rotary dies are used depend- ing on the diecutting equipment to be used. Sheeting If paperboard is received into a sheetfed carton plant in rolls, it must be sheeted in order to be able to be fed into the presses. This is the first step in the converting process, where raw material, paperboard, is converted into packag- ing. However, on an in-line, web-fed production line, sheeting is the last process to take place. In such instances, including Figure 2. A rigid box container, with sides made from chipboard. unlike a folding carton, it cannot be laid flat. Figure 3. A cartonboard mill. Photo courtesy Cascades inc. 42 FLeXO oCtober 2010 www.flexography.org FLX_Oct10_mech.indd 42 10/15/10 12:32 AM
Sustainable Fall 2010