TRAINING REPORT

ON
STUDY OF JOB SHOP TYPE INDUSTRY

SUBMITTED BY-
RISHABH GEHLOT
15119046
B. Tech, Final Year
Production and Industrial Engineering
IIT Roorkee
CERTIFICATE
 ACKNOWLEDGEMENT
First I would like to thank Mr. Jabar Singh Gehlot and Mr. Ravi
Singh Gehlot for giving me the opportunity to do an internship
within the organization. For me it was a unique experience to
be in this work shop. It also helped me to get back my interest
in industrial engineering and to have new plans for my future
career.
I would like to thank all the people also that works in the
organization. With their patience and openness, they created
an enjoyable working environment. Furthermore, I want to
thank all the engineers and students, with whom I did the
internship. We experienced great things together and they
taught us many more things regarding manufacturing of
flexographic printing machines.

THANK YOU
RISHABH GEHLOT
 INTRODUCTION

GEHLOT is manufacturer of flexographic printing machine with

37 proficient years. There stage by stage inspection and in
house production keeps them ahead of the competitors.

They do business with personal touch so all clients are like

family, and Clients are their main marketing tool.

They believe in making quality machines meticulously with

the help of highly trained workers. Providing after sales
service to customers is indispensable part of the system .
 PRODUCTS
They basically manufacture 4 types of printing machines-

 2 Color Flexo Machine

 4 Color Flexo Machine
 6 Color Flexo Machine
 8 Color Flexo Machine

VISION-
Their vision is to be the world leader in flexo machinery,
providing customers with high-quality machinery and creative
solutions that will allow their companies to prosper. To be
responsible, honest, and play fair to keep their promise
without compromising on their integrity. To minimize
downtime and wastage, resulting in an ability to offer
efficient and cost effective solutions. To ensure compliance to
the highest standards globally in production .
MISSION-
Their mission is to provide first-class quality and innovative
machine tools and service in response to the customer's
needs. Establish a world where they can seamlessly and
effortlessly transcend all the perceivable barriers to achieve
direct communication, free of all restraints, between clients
and their target audience. To take the experience of printing
beyond its physical space and make it soul stirring .
 2 COLOR FLEXO MACHINE

Features-

- The machine is suitable for printing on LDPE, HM, HDPE, PP,

BOPP, Non-Woven, Paper etc.
- Double winder & unwinder, printing speed-50 meter per min
- Reverse Printing Arrangement (2, 1+1)

Optional-

- Tension Control System

- Web Aligner

- Doctor Blade System with Ceramic Roller

- Chambered Doctor Blade System with Ceramic Roller

 4 COLOR FLEXO MACHINE

Features

- The machine is suitable for printing on LDPE, HM, HDPE, PP,

BOPP, Non-Woven, Paper etc.

- Double winder & unwinder, printing speed-50 meter per min

- Reverse Printing Arrangement (4, 1+3, 2+2)

Optional
- Tension Control System

- Web Aligner

- Doctor Blade System with Ceramic Roller

- Chambered Doctor Blade System with Ceramic Roller
 6 COLOR WOVEN SACK FLEXO
MACHINE

Features

- The machine is suitable for printing on LDPE, HM, HDPE, PP,

BOPP, Non-Woven, Paper etc.

- Trolley Web Aligner, printing speed-50 meter per min

- Surface Winder

- Reverse Printing Arrangement (6, 1+5, 2+4, 3+3)

Optional

- Tension Control System

- Corona Treater

- Doctor Blade System with Ceramic Roller

- Chambered Doctor Blade System with Ceramic Roller
 6 COLOR HIGH SPEED FLEXO
MACHINE

Features

- The machine is suitable for printing on LDPE, HM, HDPE, PP,

BOPP, Non-Woven, Paper etc.

- 4 Drive System

- Web Camera

- Web Aligner

- Chambered Doctor Blade System with Pneumatic Pump &

Ceramic Rollers
- Hot Air System

- Reverse printing arrangement (6, 1+5, 2+4, 3+3)

- Printing speed- 150 meter per min
 6 COLOR STANDARD FLEXO
MACHINE

Features

- The machine is suitable for printing on LDPE, HM, HDPE, PP,

BOPP, Non-Woven, Paper etc.

- Double winder & unwinder, printing speed-50 meter per min

- Reverse Printing Arrangement (6, 1+5, 2+4, 3+3)

Optional
- Tension Control System

- Web Aligner

- Doctor Blade System with Ceramic Roller

- Chambered Doctor Blade System with Ceramic Roller
 6 COLOR ECO FLEXO
MACHINE

Features

- The machine is suitable for printing on LDPE, HM, HDPE, PP,

BOPP, Non-Woven, Paper etc.

- Double winder & unwinder, printing speed-40 meter per min

- Reverse Printing Arrangement (6, 1+5, 2+4, 3+3)

Optional
- Tension Control System

- Web Aligner

- Chambered Doctor Blade System with Ceramic Roller

 8 COLOR FLEXO MACHINE

Features
- The machine is suitable for printing on LDPE, HM, HDPE, PP,
BOPP, Non-Woven, Paper etc.

- Double winder & unwinder, printing speed-50 meter per min

- Reverse Printing Arrangement (8, 1+7, 2+6, 3+5, 4+4)

Optional
- Tension Control System

- Web Aligner
- Doctor Blade System with Ceramic Roller

- Chambered Doctor Blade System with Ceramic Roller

 WORKING OF THE INDUSTRY
 Being a job shop type industry, manufacturing is
initiated after the arrival of order from customer.
 Mainly the customers are from Gujarat(Halol),
Maharashtra, Madhya Pradesh.
Typical Products of a Flexographic machine
 Flexible packaging materials (bags)
 Card board (liquid container, boxes)
 Labels (bottles)
 Paper (bags, wrapping paper)
 MACHINE PRINCIPLE

Flexographic printing is a letter press printing process.

The printing plate is made out of a soft material. The
low viscous ink is transferred by the anilox roller to the
plate and from there directly with low impression to the
printing substrate. One after the other the four
elemental colors (cyan, magenta, blue black) and
special or ornamental colors (like white, silver, gold,
green) are printed. Single color solid motifs can be
printed as well as multi-color halftone print. The amount
of ink transferred to the printing plate is controlled by
the make-up of the anilox roller. The print unit consist of
ink supply, anilox roller, plate cylinder and impression
cylinder. If impression is off and the ink supply is on,
the anilox roller must turn to avoid the ink from drying
in the cells.
The impression cylinder transports the substrate and
sometimes is equipped with a nip roller. The according
motor has to be sized to max. Web tension as it acts as
an infeed tension unit. As the plate cylinder has only little
impression, it can slip on the printing substrate. A
length register movement has no influence on the web
tension. Furthermore, it is possible to change the
printed format by a changing the speed of the plate
cylinder, e.g. to compensate stretch and tolerances of
the plate. Whatever movement of the plate cylinder, the
anilox roller has to follow in synchronism to avoid wear
and bad influence of the inking up.
 MANUFACTURING

 Parts of the base structure of flexo machine are

manufactured in the firm itself.
 These parts are heavy base, rope system, impression
cylinder, plate cylinder, printing plate and anilox roller.
 Other parts such as paints, printing substrate and
automation system are generally imported.

(AUTOMATION SYSTEM)

(PRINTING SUBSTRATE)
 MANUFACTURING CONT…

Firm has four manufacturing sections namely-

1. Casting section
2. Welding section
3. Machining section
4. Assembly section

1. CASTING SECTION-

Structures like flat plates, rollers, curved parts are

manufactured with the help of casting. Reverberatory
furnace is available in the casting section and permanent
mold are already available. Mild steel is used for
manufacturing of the body and Aluminum core is used for
anilox roller.
2. WELDING SECTION-

Arc welding is used for joining of rollers and pipes as well as

other joining tasks.
3. MACHINING SECTION-

Final finishing and machining of parts are done. Proper

dimensions are given to rollers and cylinders for exact
rotation time as well as the anilox roller’s surface is
smoothened. Proper teeth cutting of gears, cylinders and
other rollers are done. Many lathe, CNC, grinding, cutting,
surface finishing machines are available in workshop.
4. ASSEMBLY-

Final assembly of machine is done as well as testing too.

Substrate is used along with paints to check the proper
printing of the machine.
 CONCLUSION
It was a great internship in GEHLOT FLEXO full of knowledge. I
really enjoyed the training period. I have learnt about working
of a job shop type industry with thorough knowledge about
manufacturing of flexo printing machine.
Most of the time I used to learn from shop floor workers as well
as managerial aspect from heads.
I also saw how an organization work under extreme pressure
and how to handle it.
Overall it was a good experience.
 REFERENCES
 https://www.gehlotflexo.com/
 https://www.siemens.com/global/en/home.ht
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