Optimization of flexo process parameters to reduce the overall manufacturing cost

Akshay V Joshi

doi:10.11121/ijocta.2022.1137

Authors

Akshay V Joshi Department of Printing Engineering, P. V. G’s College of Engineering & Technology and G. K. Pate (Wani) Institute of Management, Pune, India https://orcid.org/0000-0002-8733-1747

DOI:

https://doi.org/10.11121/ijocta.2022.1137

Keywords:

Flexography, Polyethylene, Design of Experiments, Analysis of Variance, Regression

Abstract

The flexo process parameters play an important role in ink transfer and will lead to wastage of inks, substrate, solvents and printed stocks if not monitored and controlled. The work focuses on optimizing the flexo process parameters for 40 microns 3-layer polyethylene (PE) film with Blue Nitrocellulose (NC) ink to reduce overall manufacturing cost while maintaining the print quality for diaper application. An experimental design was conducted for the response Ink GSM (grams per square meter), ?E and Print Mottle with factors such as ink viscosity, anilox volume, plate dot shape and substrate opacity. The data was analyzed through Main Effect, Interaction Plot and Analysis of Variance (ANOVA). The regression models were developed for the response to validate the predictive ability of model. The process optimization resulted in reduction of Ink GSM, ?E and Print Mottle by 18%, 52% and 1% respectively. The ink consumption reduced by 18.26% with minimized print defects, thereby reducing the overall manufacturing cost.

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Author Biography

Akshay V Joshi, Department of Printing Engineering, P. V. G’s College of Engineering & Technology and G. K. Pate (Wani) Institute of Management, Pune, India

Akshay V. Joshi received Bachelor’s and Masters Degree in Printing Engineering from University of Pune, India. He was awarded Ph.D. (Engineering) from Jadavpur University, Kolkata in 2015. Dr. Akshay Joshi is working as Assistant Professor, Printing Engineering Department at P. V. G’s College of Engineering & Technology and G. K. Pate (Wani) Institute of Management, Pune, India since 1996. He is Coordinator, Board of Studies and Member, Research and Recognition Committee for Printing Technology at Savitribai Phule Pune University. His area of research is Gravure, Flexo and Flexible Packaging. Dr. Akshay Joshi has published several papers in Journals and guided candidates for Master Program in Printing Engineering and evaluated Ph.D. candidates. He is been internationally qualified as G7 Expert by Idealliance USA and implemented first G7 calibration for Gravure and Flexography printing processes in India. He is a Life Member of Indian Society for Technical Education.

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