Optimization of flexo process parameters to reduce the overall manufacturing cost

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 Nitrocellu...

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Bibliographic Details
Published inAn international journal of optimization and control Vol. 12; no. 1; pp. 66 - 78
Main Author Joshi, Akshay V
Format Journal Article
LanguageEnglish
Published Prof. Dr. Ramazan Yaman 01.01.2022
Balikesir University
Subjects
Analysis of Variance
Design of Experiments
Flexography
Mühendislik
Polyethylene
Regression
İstanbul
Türkiye
Regression
Polyethylene
Design of Experiments
Analysis of Variance
Flexography
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Summary: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.
ISSN:2146-0957
2146-5703
DOI:10.11121/ijocta.2022.1137