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CONVERSION

Desarrollo de Negocios SSSA Region 2010

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Agenda

Conversin:

- Corte y Troquelado

- Delaminacin / Laminacin

- Otros Procesos de Acabado final

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Corte y Troquelado

Corte: Se caracteriza por se bsicamente lineal. Tipos de Corte: Con material esttico Guillotinado Slicing o Trozado Con material en movimiento Corte con hojilla Slitting Corte con cuchilla circular Corte Yunque

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Corte y Troquelado
Troquelado: Se caracteriza por ser un corte con alguna forma definida. Formas de Troquelado: Puede ser troquel pasado o troquel a medio corte. Con material esttico Corte de galletas (cookies) Troquelado Plano Corte de piezas metalrgicas Con material en movimiento Troquelado Rotativo

Nos concentraremos en el troquelado rotativo, de rollo a rollo, en banda angosta, para produccin de etiquetas autoadhesivas.

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Troquel - Diagrama

HYDRA-JACKSCREW HYDRA-JACKSCREW
CAM LOCK ASSEMBLIES (2)

BRIDGE PLATE TRUCK ASSEMBLY

ROTARY DIE ANVIL ROLL WIPER ASSEMBLY (QTY 2)

LOWER SUPPORT ROLL

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Troquel - Diagrama

HYDRA-JACKSCREW

CAM LOCK ASSEMBLY BRIDGE PLATE TRUCK ASSEMBLY WEB FELT WIPER ASSEMBLY (QTY 2) ANVIL ROLL LOWER SUPPORT ROLL
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Corte y Troquelado
Troquelado:
La operacin se lleva a cabo por presin de una superficie de corte afilada contra el facestock el cul est soportado por el liner y un Anvil roll. La presin corta o revienta el facestock y el adhesivo. El troquel es una herramienta diseada para cortar repetidamente un material de acuerdo a un patron y puede ser fabricado en un contorno plano o cilndrico. Troquel Cama Plana - Son laminas de acero afiladas que estn sostenidas a una plancha movible. La plancha se baja hasta el yunque estacionario en el que el rollo se detiene momentaneamente y luego retorna a su posicin inicial.

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Corte y Troquelado
Troquelado:

Troqueles Magnticos: Son troqueles grabados en hojas metlicas planas delgadas, las cuales se sujetan alrededor de un cilindro magntico de una prensa rotativa. La profundidad de la cuchilla y la durabilidad de la misma es significativamente menor a la de un troquel grabado directamente en un cilindro, pero los costos son muy competitivos, as como los tiempos de entrega.

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Corte y Troquelado
Troquelado:

Troqueles Rotativos: Son troqueles grabados en un cilindro slido donde los bordes de corte se forman por remocin del material en la superficie del cilindro, creando as una figura en relieve afilada que troquela o corta. Los troqueles cilndricos rotativos son tpicamente ms caros pero por lo general durarn mucho ms y se fijan muy bien para figuras y diseos difciles.

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Corte y Troquelado
Troquelado:

Portadores del Troquel: Son una parte importante de los troqueles pues son los cuellos a cada lado del cilindro, que ayudan a posicionar el troquel sobre la superficie a cortar con una distancia MUY precisa desde el rodillo Yunque (Anvi roll) hasta la cuchilla. Con estos portadores se controla la profundidad del corte. Esta distancia precisa o espacio est determinada por el calibre del liner que ser usado. El calibre del liner es crtico en el proceso de troquelado pues ste cumple la funcin de ser una extensin del rodillo Yunque. Este liner soportar al adhesivo y a la cara de impresin para que puedan ser cortados. Si el liner cambia de espesor, la cara de impresin y el adhesivo sern presionados y podran ser sobre troquelados (que originar problemas de dispensado) o en su defecto no ser troquelados lo suficiente (problemas en conversin).

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Corte y Troquelado
Anvil Roll o Yunque El anvil roll es un rodillo de gran precisin hecho de acero con soportes laterales. Este rodillo es la superficie que soportar el material en el momento de ser cortado completamente o troquelado. Cuchillas del troquel Las cuchillas son bordes afilados que han sido grabados en una variedad muy amplia de configuraciones y diseos. El material de las cuchillas est basado generalmente dependiendo del material que se troquelar, as como el ngulo del filo de dichas cuchillas. Tpicamente, las cuchillas para papel se disearan con un angulo de 28 grados, mientras que para pelculas tendr un ngulo de 21 grados. Sin embargo los valores pueden variar entre los diferentes productores y entre una pelcula y otra. Presin de las cuchillas La mayora de los productores recomiendan una presin de 120# por pulgada lineal, al ancho de la cuchilla. Esta es una presin combinada a cada lado del troquel, es decir cada jack bolt debera tener 60# de presin por cada pulgada. Vida de las cuchillas La duracin de las cuchillas o troqueles depender del material que este siendo cortado. Cualquier material contienen rellenos y recubrimientos abrasivos que reduciran la vida til del troquel, adems las tintas opacas de screen tambin reducirn la vida. Algunos productores de troqueles hablan de un numero de impresiones mnimas, pero en general la industria no se compromete. Pueden ofrecer recubrimientos para alargar la vida de las cuchillas. Las pelculas requieren un borde ms afilado que los papeles, debido a la conformabilidad de las pelculas. Cuando se troquela un papel con sobrelaminacin de pelcula los troqueles deben ser diseados para el el film de sobrelaminacin. (Problemas: encogimiento del film y explosin del papel antes que el film sea cortado).

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Corte y Troquelado

Concepto de troquelado a medio corte

A B C D E Face Stock Adhesivo Liner

e = Espesor del Liner A=Troquelado pasado. Rompe el Liner B=Troquelado que semi-cort el Liner C=Troquelado marcado. Debilita la capa de silicona D=Troquelado correcto E=Troquelado incompleto. No cort completamente el face-stock.

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Corte y Troquelado
Problema de Troquelado: Son de varios tipos:

Relacionados con el estado del troquel Relacionados con el estado de la estacin de troquelado / Anvil Roll / espesor del liner. Suciedad
NOTA: Para todo anlisis, estudiar una variable a la vez

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Desbasure
http://www.youtube.com/watch#!v=KDHHorfdwtU&feature=related

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Desbasure

El desbasure de la matrix es el proceso de remocin del residuo del facestock, una vea se ha hecho el proceso de troquelado. V El desperdicio es una web completa que se separa a otro rodillo en la prensa (ver el video). Dado que la mayora de la cara de impresin permanece con el liner en forma de etiqueta, la fuerza de retiro de dicha matrix es crtico para un proceso continuo. El proceso de desbasure depende de:: - Fortaleza del material - Nivel del release del liner - Diseo de la etiqueta

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Laminacin/ Delaminacin

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Delamination and Relamination Delamination/Relamination (delam/relam) is the term used to describe the process of separating the facestock from the release liner either during the converting operation or off line on another piece of equipment. Delam/Relam has been used for years to separate the label material so that information or graphics can be printed on the adhesive. This information is typically used as instructions for use of a product or ingredients. The labels are applied to clear plastic or glass containers with clear products inside so the message can be read through the bottle and product. Due to the fact that the adhesive is contaminated by the printed ink, it is strongly recommended that complete testing be completed to insure the adhesion of the label to the substrate has not been affected. Delam/relam also presents the opportunity to print a deadening agent on the adhesive, usually a heavily filled ink or a varnish. This can be done to simulate a patterned adhesive coat out of a solid gum product. Many times select cross web patterns are created that can not be produced on a coating machine. The affect of adhesive deadening can change with age as the adhesive flows and absorbs the printed ink. In some situations the deadened area will remain for years whereas in others, the adhesion could return to near normal within weeks. Testing is highly recommended in all applications. In special situations, delam/relam can be used to lower the release level of the product to aid in stripping the matrix. This can be especially useful in situations with difficult die configurations or material with higher than normal release. With all of the potential advantages for using delam/relam on a pressure-sensitive material, there are just as many reasons not to employ the technique: The delamination process can cause excessive static build-up on press, which when discharged, can fracture the silicone coating. When the label material is relaminated, the adhesive will adhere to the exposed liner causing higher than normal release levels. In addition, the force required to delaminate the label material can remove a chunk of silicone/paper that was not well bonded to the liner surface. The result will be a welded spot that will could cause a web break either the converting or application process. The static created during delamination can also attract dust and dirt. Particles laminated in the web will fracture the silicone coating which will result in adhesive bonding to the liner, causing areas of high release. The delamination process has the potential for scratching the silicone coating if it comes in contact with anything, with the result being high release. The delam/relam process can result in excessively low release levels, resulting in labels predispensing on press or on the applicator. Typically the final release on a relaminated product is less that 50% of the original release. With age the release will begin to increase however studies have shown that the results are inconsistent. Some adhesive/liner combinations will regain as much as 75% of the original release level, whereas others may never increase at all. It could also result in excessively high release if the silicone was not quite as good as it should have been. Delam/relam will magnify any silicone deficiencies that might not have been a problem through the normal process.

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Otros procesos de acabado

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FINISHING PROCESSES Finished labels can be finished in rolls, sheets, or fanfolded. As with any printed material, printed labels could be processed in any bindery post press operation. Roll labels are often made into master press rolls which are run through inspection equipment before packaging into final form. Inspection equipment can be table top or a stand-up piece of equipment. Inspection equipment will wind roll-to-roll, often employing a strobe light and an optical counter to aid the operator. Rewinding can be on cores or coreless. Finished rolls of labels can be used manually, or for automatic dispensing. Sheeted labels can be used as inserts to a product, packaged for resale or for sheet fed printers. Sheeted labels may be packaged on-press or palletized for later packaging. Sheeted labels can cull out waste immediately at press. The critical aspect of sheeted label production is keeping trim (slitter) and sheeter dust to a minimum. Edge standards need to be established and monitored so that tooling can be replaced when needed. Fanfolded labels are typically used in a computer printer, where this is the traditional form of print media. Fanfolded labels may also be used in automatic labeling equipment to provide a "non-stop" supply of labels (the lead edge of a fanfolded stack can be taped to the tail edge of the previous stack to extend running.) Fanfolding is typically done on-press, where product can be immediately inspected and packaged. Some off line fanfolders are in use to convert rolled labels into fanfolded stacks.

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pdfMachine A pdf writer that produces quality PDF files with ease! Produce quality PDF files in seconds and preserve the integrity of your original documents. Compatible across nearly all Windows platforms, if you can print from a windows application you can use pdfMachine. Get yours now!