INDUCTION TRAINING REPORT

Submitted To:
Holostik India Limited.
Corporate office.
Sec-2 NOIDA.-India
Submitted by:
-Urmilesh Singh
International Marketing Division,
Holostik India Limited.
+91-9540256120
[email protected]
[email protected]
 ACKNOWLEDGEMENT

This report will be incomplete without a proper acknowledgment of the debt to

many persons, who made it possible. It is my great pleasure to acknowledge
those whose active help and support make this report possible in the present
form. First of all I express my sincere gratitude to Mr. U. K. Gupta, Chairman-
HOLOSTIK GROUP, who introduced Holography to us. I would also like to
express my gratitude to Mr. Shobhit Gupta, Director-International Marketing
Division- Holostik India.

It is the endless guidance and constant encouragement of Mr. Navneet Goel and
all the HODs Engineer’s, Supervisors, Executive Engineer’s, of HOLOSTIK
and I would like to express my heartfelt gratitude to them. I am deeply indebted
to all people for insisting in me the drive to learn and for inculcating in me the
discipline to think clearly. Definitely the knowledge, I received during this
training session was a lifetime experience and it will serve as a foundation for
my career of Holography. I am thankful to all who make the stay enjoyable. I
am thankful to all technical and non-technical staff of the Holostik who helped
me directly or indirectly during this training program.

-Urmilesh Singh
International Marketing Division,
Holostik India Limited.
+91-9540256120
[email protected]
[email protected]
Executive Summary:

Holography is a technique that allows the light scattered from an object to be recorded and
later reconstructed so that when an imaging system (a camera or an eye) is placed in the
reconstructed beam, an image of the object will be seen even when the object is no longer
present. The image changes as the position and orientation of the viewing system changes in
exactly the same way as if the object were still present, thus making the image appear three-
dimensional.
Holography also can be defined as “Creation by interference of two beam and
recreation of objects is called Holography.”
Hologram is an interference pattern formed as a result of reference light encountering
formed as a result of reference light encountering light scattered by an object and
stored as such on a light sensitive emulsion.
Hologram is a technique of writing. It also can be said that it is an illusion.
The holographic recording itself is not an image; it consists of an apparently random structure
of varying intensity, density or profile.
The aesthetic appeal and commercial usefulness of holography are both related to the ability
of a hologram to store a three-dimensional image. Unlike ordinary photographs, holograms
record both phase and amplitude information. Because phase is a relative property,
construction of a hologram requires a “reference beam” in addition to the light reflected from
an object’s surface.

Additional requirements include a powerful, coherent, monochromatic light source (e.g. a

laser, whose workings you should understand); a vibration-free flat surface; some common
optical devices; and photographic plates, chemicals, and a darkroom.

A hologram can be made by exposing a photographic plate to the interference pattern made
by the reference and object beams. The plate is then developed and dried. When illuminated
by a reference beam similar to the original one, it recreates a three dimensional picture of the
object.

There is nothing mystical about this recreation, and you can understand how it works with the
help of some Fourier transform mathematics.

Worldwide, counterfeiters rob almost Thousands of Billion dollars of legitimate business

turnover! This is a seriously threatening issue - while the counterfeit product absorbs your
goodwill, it passes on its own shortcomings to your products. The results can be disastrous.

Our Marketing Gurus while writing Principles of Marketing overlooked the 5th P* -
PROTECTION (Other 4ps are- Product, Price, Place Promotion). Protection that your brand
needs from a look alike or a counterfeit.

In today's context, where huge amount of money, effort and time are being spent on building
up brands, the least your product deserves, but seldom gets, is the 5th P.

The very concept of Holograms has emerged from the need to have a mark of authentication
that is simple enough to be identified by even an untrained or illiterate eye, and yet
sophisticated enough to make it near impossible to be duplicated or replicated.

A Hologram is the culmination of several processes involving physical, chemical and artistic
inputs. The extremely high level of technology that goes into its manufacture coupled with
the exclusivity of the technology makes it far beyond the reach of a counterfeiter.

*****************
HOLOSTIK INDIA LTD.-HIL-Commitment of being the best.
Incorporated in February 1991, Holostik India has played a pioneering role in the
introduction and popularization of security holograms in India. An ISO 9001: 2008, ISO:
14001:2004 and OHSAS 18001:2007 certified Holostik Group Company; we are a leading
manufacturer of holograms and allied products in India.

We are an undisputed market leader for security holograms in India enjoying more than 50%
of the total market share. We have been pioneering innovative and customised holographic
solutions for varied industries, for the more than 20 years. Proud though we are of our
heritage, we constantly look to the future.
Our Global Presence:
 Our network includes

14 centers at strategic locations in India

10 offices/representative locations abroad

 At present, Holostik India Ltd. is exporting to more than 41 countries worldwide

 We have 4 State-of-the-Art manufacturing facilities

Our Milestone:

 Undisputed market leader having more than 50% market share in India, in
security holograms
 One of the largest manufacturers of security holograms and holographic products in
the world.
 Securing products for more than 8000 satisfied customers in private & government
sector customers of INDIA as well as abroad.
 Fully integrated, 4 State-of-the-art manufacturing facilities
 1st Holography company in the world to implement SAP ERP
 Chairman awarded the prestigious Brian Monaghan Award 2008 by IHMA
(International Hologram Manufacturers Association), for his contribution in the world
of holography
 CMD has received the Business Sphere Award for most successful leader in
manufacture of quality holograms (2005-06)
 Holostik India was rated among the Top 500 mid-size companies in India by the Inc.
magazine (India) in 2010

IHMA Excellency Awards

 New holography product
 Promotion / Illustration
 New Labelling Solution
HoMAI Excellency Awards

 New Applications
 Security / Authentication
 New Holographic Product
 Highest growth in holographic product sales
Holostik Differentiators:
We specialize in holography-guided by our spirit for innovation.

1. Cutting Edge Technology

 Most updated techniques to develop authentication, anti-counterfeiting and anti-

tampering solutions
 1st holographic company to run on SAP to keep client information as secure as
possible and provide real time information to our sales offices located at different
locations in India
 Sophisticated 3 master origination facilities with state-of-the-art laboratory equipment
up to 1,20,000 DPI
 Focus on R&D, to produce security features (patented), considered to be the best in
the world. i.e. Layergram, Depthogram, Kinnetgram, Pixelram etc

2. Infrastructure
 4 Fully integrated and modern manufacturing facilities with state-of-the-Art
laboratory, under one roof
 Network includes 14 centers in India and 10 locations internationally
 Reach offers guaranteed service to customers within 2-6 hours
 One of the world's largest security hologram manufacturing facility

3. Quality & Service

 An international presence
 Comprehensive in-house quality control measures with secure environment
 Certified under ISO 9001: 2008, ISO: 14001:2004 and OHSAS 18001:2007.
 Complete suite of services like design, origination, manufacturing and distribution to
help steer clients from concept to launch
 One of the best internationally trained and highly qualified manpower

4. Experience in Security domain

 We have been providing security solutions since 1991.We understand security- It is

the essence of our business.
 One of the best security parameters available in the world
 3-Tier security system at the manufacturing locations: High-security environment
(most vital in the holography industry) with round-the-clock vigil by security
personnel, video-surveillance and access control systems
 Ensure 100% guarantee of confidentiality/secrecy of customer-related information

HIL have 4 Manufacturing Units.

HIL Rudrapur.
HIL Noida.
HIL Chennai.
HIL Raipur.
Hologram:

Hologram is made by laser light. All effect came through laser light. We can create different
type of effect with help of Laser light. In comparison to printing we can show, Motions, 3-D
effects, Channel effects, Kinetic Movements, in Hologram (without using of Colours).
Hologram also can be define as “Image formation by wave front reconstruction”, “Lens less
Photography”, or “Freezing an image on its way to your eyes and then reconstruction it with
a laser.”

Type of Hologram.
On the basis of Level of security and Master Origination we can divide Hologram in 4 types
as under:
 Layergram.
 Pixelgram.
 Lineargram.
 Lithogram.

Layergram.
o Foreground.
o Embossed effect.
o Micro text.
o Concealed Text.
o Channel effect/switch/Flip-flop.
o Kinnetgram.
o Modulated depth Effect.
o True Color Photo.
o Kinetic Movement.
o Dead color.
o 2D-3D Background.

Pixelgram.
o Full visible with dynamic effect.
o 4 Channel Effect.
o True color Channel-1.
o True color Chanel-2.
o Pearlogram.
o Covert laser viewable text .
o Gradient effects (double).
o Pure 3-D Globe Model.
o 2D-3D channel Depth effect.
o Raster Text.
o Animated Book/Bird.
 o Animated covert laser viewable.
o Circular depth effect.
o Sparkle effect.
o Micro text.
o Guilloche pattern.

Lineargram.
o Full visible with dynamic effect
o Miniswitch.
o Pearl with emboss effect.
o Bas relief effect.
o Micro photo.
o CLR animated multiple image.
o Different CLR text at one point.
o Channel Effect.
o Gradient effect.
o 2D-3D Depth effect.
o Kinetic Movement.

Lithogram.

o Silver Metallic effect.

 Introduction of HIL Rudrapur.

Major Departments:
 Human Resource Department.
 Master Shooting Department.
 Electroforming Department.
 Embossing Department.
 Lamination Department.
 ADC Department.
 WADS, HSF, STRIPS Department.
 Quality Control Department.
 Commercial Department.
 Production Planning Department.
 Store Department.
 Dispatch Department.
 Wide web Printing Department.
 Pouching & Shrink Sleeve Department.
 R&D Department.
 Master Shooting Department.

Hierarchy: There are 4 people working in this department.

1. Mr. M.P. Himansu.
2. Mr. J. Mohan.
3. Mr. D. K. Singh.
4. Mr. Navneet Agrawal.
Process Flow:
Artwork-----Redesigning according to software----Shooting -----Master
Development----Electroforming----Recombining on Acrylic Sheet.
Duties and Responsibilities:
 Master Designing.
 Master Recording.
 Master Shooting.
 Master Development.
 Master Recombining.
Internal Vendor, Customer and Co-ordination:
 Design Department, Head Office, Electroforming, QC.
Introduction of Machine:
1. 2D/3D Machine:
 Manually, Old Process.
 Film Came from Artwork on basis of Color.
 Alignment.
 After Alignment image on Mask Plate.
 Recording on Glass Master.
 Development of Glass Master.
 Developed Glass master send to electroforming.
 True Object Shooting.
 Time Taking Process.
Major Raw material:
 Film.
 Mass Plate.
 Developer.
 Photo resists Plate.
Things to be check:
 No Vibration.
 Temp (18-24ºc).
2. Kinemax-Sec High set up:
 New Process.
 Soft copy came from Artwork.
 Redesigning of Soft copy from Artwork.
 Master Recording-Glass Master.
 Single image recording.
 Glass Master Development (Single image glass master).
 Send to electroforming department.
 Receiving of 10µ SHIM.
 Recombining on Acrylic Sheet.
 Acrylic Master Handover to electroforming department.
Specialty:
 Litho Effect (Silver Metallic effect).
 Less time taking.
 Pixel to Pixel shooting.
 Auto recording.
3. Recombining Machine:
 Single image to multiple images is called
recombining.
 After receiving 10µ SHIM from electroforming
selection of die.
 Putting of SHIM on die according to availability.
 Pressing of SHIM on acrylic sheet.

*************
 ELECTROFORMING DEPARTMENT.

Electroforming is basically formation of Electron using electricity.

Hierarchy: Mr. Puneet is HOD and there are 6-8 people are working in this
department.

ELECTROFORMING Process:
 Receiving of Glass Master from Master Lab.
 Silvering (because Glass Master is bad conductor of
electricity).
 Electroformation .
 MNV (Mother Negative)
 MPV (Mother Positive)
 Negative 10µ SHIM, Send to Master lab for Recombining.
 Recombining on Acrylic sheet
 Silvering of recombined Acrylic sheet (because Acrylic
Master is also bad conductor of electricity).
 Electroformation – Passivation.
 MNV (Mother Negative-More than 100µ)
 MPV (Mother Positive-More than 100µ)
 ONV (Only negative) 40µ SHIM, Send to Unit I (Narrow
Wave- Hard Embossing) for Embossing Department and
55µ SHIM Send to Unit II (Wide Wave-Soft Embossing).

Master of every Job moved to STRONG ROOM (30ºc temp).

Master of every job contains:

 Single image MNV.
 Single image MPV.
 Acrylic master.
 Acrylic MNV.
 Acrylic MPV.
 Acrylic ONV.
 40µ/55µ SHIM.
Major Raw material:
 Ni Sulphamate.
 Silvering Solution.
 Sulphamic Acid, Boric acid.
 Ni chloride, Anti pit.
 Potassium Die Chromate.

Problem comes in Electroforming:

 Thickness (High & Low).
 Croning (thickness in centre).
 Wrinkle.
 PIT (Back side).
 Nodule (small dots due to high electricity).
 White/ Black spot.
 Foggy spot.
 Roughness.
 Dent.
 Scratch.
 Multi shiny spot.
 Burning.
 PIN hole.
 Dullness.
 Shooting problem.
 Recombining problem.

**********************
 EMBOSSING DEPARTMENT

Hierarchy: Mr. Vaibhav is HOD. Mr. Pandey, Mr. Sharad and Mr. Abishek are
assisting him.

EMBOSSING: Embossing is a Mechanical Process. There is no use of Ink.

 SHIM clamping sheet.
 Clamping of SHIM on Roller.
 Side roller can be made of Metal and Rubber and Centre
Roller is made of Metal.
 Pressure and winder tension.
 Embossing Inspection of Gapping and scratches etc.

Major Raw material:

 Metalized Polyester.
 HRI Film.
 Metalized Polyester can be divided on the basis of
thickness.
o 16µ-HSF.
o 24µ-HSF, CTS, NTS.
o 36µ-CTS, NTS.
o 50µ-CTS, NTS.
 Metalized Polyester can be divided on the basis of
Colour: 12-13 standard colours.
 Metalized Polyester can be divided on the basis of
Temper properties.
o CTS: Cold transfer Security.
o NTS: Non Transfer Security.
o HSF: Hot Stamping Foil.
o Partial Temper (Text temper, Honeycomb).

BASIC CONSTRUCTION OF Metalized Polyester:

There are three layers:
1.Coverds: Al (Metal)
2.Lacquer Coating (It can be coloured of not coloured then
Silver)
3.Clear PET.
 LAMINAITON DEPARTMENT

Mr. Bakuni is HOD and there are 3 GET.

Process:

 Embossed foil
 Process – Adhesive on Release paper/ Embossed foil.
 ADC department/ WADS.

Vendor:

 Embossing department.
 Store
Customer:

 ADC, HSF & WADS.

Raw Material:

 Release Paper:
o 80GSM (175mm & 170 mm width).
o 88GSM (175mm & 170 mm width).
o 120GSM (175mm & 170 mm width).
o 62GSM (175mm & 198 mm width).
Smaller the size of hologram and higher the GSM of release paper.

 Adhesive:
o Water Based (Normal On books)
o HMPS (Hot melt Pressure sensitive- Liquor, Metal)
o Solvent Based (On cloths)
o PU (Polyurethane - WADS).
Products:

 Holograms.
 WADS.

Type of Lamination:

 Water Based (Normal On books)

 HMPS (Hot melt Pressure sensitive- Liquor, Metal)
 Solvent Based (On cloths)
 PU (Polyurethane - WADS)
Machines:

 HMPS -3machines:
o Adhesive used brand name –Hankel.
o Adhesive applied on release paper.
o Rubber Based Hot melt adhesive.
o We used chillers to make it cold.
o 18-20GSM coating.
o As speed of the machine goes higher the flow of adhesive goes
higher.

 Water Based- Machines:

o Adhesive applied on embossed foil.
o Water based adhesive.
o Use of Oven and Blower to make it dry.
o PU Lamination can be done on this machine.
o In PU lamination we use Aluminium Foil (Al foil-30µ& 40µ) and
holographic NTS film.
o In case of WADS, after PU lamination, laminated foil we keep it at
45°c for 24 hrs in hot room for curing.

 HMNPS:
o Hot melt non pressure sensitive adhesive.
o This is a type of heat sensitive adhesive stuck to the surface
(substrate) when heat is applied.
o Hot melt Burfey Adhesive.

Adhesive used on the basis of Foil:

CTS & NTS Foil:

 Water Based (50% water & 50% Glue).
 Maximum use for paper, book substrate.
 HMPS-Maximum use for wooden, Glossy, Strong bonding.
HSF spool:
 Paper Grade (when paper will be substrate).
 Plastic Grade (when plastic-PVC i.e. Pan card will be substrate).
 Tristar Grade (used for cloths i.e. Bombay Dying).

Use of HMNPS adhesive:

 Shrink Sleeves.
 Mirrors
*************
 ADC- AUTO DIE CUTTING DEPARTMENT

Mr. Lal Singh & Mr. Deep Kumar and more than 60 assistants.

Role and responsibility:

 Daily production Issues.

 Daily production plan.
 Daily production report.
 Machine maintenance.
 Die Maintenance.
 Manpower adjustment and Utilization.
PROCESS:

 Laminated Roll
 Selection of Die as per production order.
 Cutting as per requirement.
 Editing and slitting.
 Sheet Inspection of:
 Black spot.
 Scratches.
 Die Cutting.
 White spot.
 Adhesive problem.
 Counting.
 Numbering if required.
 Final Checking and packing.
 Dispatched Department.

There is two type of Die Cutting:

1. Manual Die Cutting-Not in use.

2. Auto Die Cutting.

PACKING PROCESS FLOW:

 100 sheet in a pouch.

 Cake Box (200sheets).
 Pasting of cake box in a slip.
 Box packing slip- It contains the information of:
 Name of Job
 Sr No.
 No of Sheet.
  No of hologram.
 Final Packed.

THREE TYPE OF DIE CUTTING MACHINES- 10 Machines:

1. FLATE BED DIE CUTTING (FBD)-7 Machines:

 We can run any job.
 Less speed.
 150 stroke/ Minute.

2. ROTTARY DIE CUTTING-2 machines:

 Non- Registered and excise job can be done.
 70 meter/ minute.

3. ABG DIE CUTTING-1Machines:

 Both job (Registered and non registered) can be
done.
 Advance machine.
 40 meter/Minute.
 Single color printing (Flexo) also can be done.
 Cold transfer available (adhesive or image).
 Slitting also can be done.

Advantage of ABG M/c:

 Registered design can be cut.

 As per requirement we can cut the sheet.

Norms for Auto Die Cutting:

 Cutting should be as per requirement.

 Pressure on Sheet.
 Cutting should not be off.
 No deep die.
 Release paper should not cut.
 Sheeting should be perfect.
Type of DIE:

Based on SHAPE:

Sharp corner.
Round Corner.
Circular.
 Ellipse Corner.
Umbrella.
Zigzag.
Special etc.

Based on Size:

Different Size.
8mm-250mm (Max Length).
190 mm Width (Max).
8mm x 5mm the minimum possible size (BPL).

Based on Material:

Metal:-
o Flexible.
o Wrap on Magnet.
o Bigger life.
o Costly.
o Imported from Germany.
Wooden:-
o Wooden Based Metal Blade.
o Indian Made.
o Laser light cutting Blades.
o Cheaper.
o Not good in sharp corner.
o Less life.
EDITING-7 Machines:

Missing Filled.
Off Centring out.

Slitting- Spooling-3 Machines:

Slitting as per requirement.

Inspection and Counting:

No of hologram in a spool.
Direction of Spool.
Vertical & Horizontal.
Numbering:

 THERMAL PRINTER- 4 Machines:- Printing on Sheet & Spool

both are possible.
 Features: Costly, use of thermal ribbon, heat transfer,
Alpha Numeric- Random, sequential, identical, logo
picture, and barcode can be printed.

 LASER PRINTER- 6 Machines:- Printing on Sheet & Spool both

are possible.
 Features: Use of laser lamp, burn the metal, Alpha
Numeric- Random, sequential, identical, logo picture,
can be printed. Barcode can not be printed in laser
numbering. Laser numbering is inside of the foil and
others are on surface of the foil.

 UV PRINTER:- Printing on Sheet not possible.

 Features: Use of UV ink, Alpha Numeric- Random,
sequential, identical, logo picture, and barcode can be
printed.

 INKJET PRINTER:- Printing on Sheet not possible.

 Features: Use of Black ink, Alpha Numeric- Random,
sequential, identical, logo picture, and barcode can be
printed.

BARCODES: A series of vertical bars and spaces carrying information. It is a

optical representation of data relating to the object to which it is attached.
Type: It is of two types:
 One dimensional (1-D).
 Two dimensional (2-D).

 One dimensional (1-D):

 It is very old, data storage is very low, takes a lot of space.
Simpler to construct, liner barcode, bars and spaces, numeric
and alphanumeric.

 Two dimensional (2-D):

 It is very new, data storage is high, less space, difficult to
construct, Geometric Barcodes, dots & rectangles, Numeric
and alphanumeric.
Bar-coding on Hologram: Bar-coding on Hologram can be done but for this
purpose we need monochromatic white background. In holograms there is less
size and good readability. Special scanner is required to read the barcode on
hologram.

PLOTTER:

It’s a die cutting machine for sampling.

*************
 HSF WADS AND STRIPS DEPARTMENT

Mr. Mahendra Sharma –HOD, Mr. Ashish and Mr. Harish are assisting him.

Duty and responsibility of individual:

 Adhesive checking.
 Release paper checking.
 Checking of Raw Material.
 Checking of GSM.

HSF Process:

 Embossed Film
 Coating of Adhesive.
 Strip Cutting.
 Packing and dispatch.

WADS Process:- Harish Sharma.

 Embossed Foil.
 PU Lamination with Al foil.
 Wax lamination with Board paper.
 Die Cutting- 150 Stroke/Minute (approx).
 Sorting on the basis of wrong cutting, black spot, Al foil problem,
Roughness.
 Packing (200 WADS in a poly tube) and dispatch.
 Layers in WADS:
 Paper board.
 WAX
 Embossed foil.
 PU adhesive.- Polyurethane- once the bond made it
cannot separate without breaking. Component of PU:
 Ethyl Acetate.
 4511R-Rasin.
 4511A-adhesive
 Al foil. Two Type:
 Poly (30µ& 40µ)
 Non Poly (Blister- 24µ)

*************
 QUALITY CONTROL DEPARTMENT

Mr. Saurabh is HOD and there are 3-4 other people assisting him.

Major Responsibility:

 Sampling.
 Raw material inspection.
 Online Inspection.
 Customer complaint and Support.
Sampling:

Two type of Sampling:

 DGM- Diachronic Glass Master.

 Sample request.
Sampling Process:

 Artwork.
 Customer artwork.
 Artwork approvals.
 Artwork from Head Office to Master Lab.
 Acrylic Glass master.
 SHIM preparation at Electroforming.
 Embossing.
 Lamination.
 Auto die Cutting.
 Finalization-Inspection
 Master lab Approval.
 QC approval.
 Sample sends to Head Office for customer
Approval.

Raw material inspection:- Major Raw Material:

I. Foil.
II. Adhesive.
III. Release paper.
IV. Packing materials

Inspection of FOIL.

o 16µ-HSF.
 o 24µ-HSF, CTS, NTS.
o 36µ-CTS, NTS.
o 50µ-CTS, NTS.
o CTS: Cold transfer Security.
o NTS: Non Transfer Security.
o HSF: Hot Stamping Foil.
o Partial Temper.
Inspection of Adhesive.

o Water Based (Normal On books).

o HMPS (Hot melt Pressure sensitive- Liquor, Metal).
o HMNPS (Hot melt Non Pressure sensitive- Shrink sleeves, Strip).
o Solvent Based (on cloths & on NTS).
o PU (Polyurethane - WADS).

Inspection of Release paper.-Dust, DOT, Spot, GSM etc.

o 80GSM (175mm & 170 mm width).

o 88GSM (175mm & 170 mm width).
o 120GSM (175mm & 170 mm width).
o 62GSM (175mm & 198 mm width).
Inspection of packing materials.

o Core:
 Plastic.
 Paper.
o Boxes.

Online Inspection:

Online inspection of Embossing:

o Roll no.
o Foil width.
o Foil thickness.
o Form (sheet spool HSF).
o Foil color.
o Foil temper type.
o Direction of Hologram.
o Curling.
o Center roller temp.
o M/c Speed.
o Roller pressure.
 o Unwinding tension.
o R/w tension.
o Image quality.
o Brightness.
o Black spots.
o Whiteness/ Matty effect.
o Back ground visibility.
o Panel Gap.
o Scan Mark.
o Printing line.
o Tempering with tape.
o Material Comments.

Online inspection of Lamination:

o Lamination substrate.
o Lamination substrate width.
o Lamination substrate GSM.
o Adhesive type.
o Temper type/check.
o Adhesive name.
o Direction of Hologram.
o Curling.
o Machine speed.
o Laminator pressure.
o Temperature.
o Coating pressure.
o Unwinding 1 tension.
o Unwinding 2 tension.
o Stretchibility of embossed film.

Online inspection of Lamination:

o Slitting width (MM).

o Form (strip/spool/HSF).
o Tamper type.
o Direction of Hologram.
o Curling.
o M/c Speed.
o Unwinding tension.
o Centering.
o Core Type.
 o Core I.D.
o Length or nos of Hologram in one Spool.

Online inspection of ADC:

o Form (spool/sheet)
o Temper type.
o Curling.
o Total no of UPS.
o Size of Hologram.
o M/c speed.
o Image Quality.
o Brightness.
o Quality of Die cutting (Centring, Deep die etc.).
o Shape/corner of Hologram.
o Releasing of Hologram.
FOR ABG:
o Unwinder Pressure.
o Rewinder Pressure.
o Die Pressure.
o Total Machine Pressure.

Online inspection of WADS:

o ST size and Actual Size (mm).

o ST thickness and Actual thickness (µ).
o ST WT and Actual WT.
o Heat Stability (No of Delamination should be Zero).
WAX lamination:
o GSM of Board paper.
o Board Width (mm).
o Wax GSM.
o Machine Speed.
o Temperature.
o Heat Stability.
o Bonding of Board & Foil.
o Wax color Variation.

Customer complaint and Support.

Information Required by QC:

 SUBSTRARE.
 SAPMLE APPROVAL
 PRODUCT KNOLEDGE
 STORE DEPARTMENT

Mr. Vipin Huria is HOD. Mr. Mahendra and 4-5 persons are there to assist him.

5 Store. All Raw Materials stored at normal room temp and pressure. Only
Tygent Ink stored at A.C.

Role and Responsibility:

Material unloading.
Checking with Quality Control.
System-in in Stock.
Release the material as per requirement.
Stock maintenance as per below shelf life:
 Al foil/PE- 3 year
 HMPS adheshiv-1 year
 Wax-1 year
 Water based adhesive-1 year
 Paper and plastic grade adhesive-3 year
 HMNPS adhesive-1 year
 Nickle Sulphamate-1 year
 Solvent-1 year
 PU Adhesive-1 year
 Stamping Foil-5 year
 Release paper-5 year
 Boric Acid-5 year
 Nickle chloride-5 year
 Charcole activated-5 year
 Ferric chloride-5 year
 Distilled Water-5 year
 PIT Fire-5 year
 Acetone-5 year
Norms:

 Standard norms.
 Raw Material allocation should be as per pre-define place.
 There is different self life for different product.

GRN –Goods receiving Note with store location. It carries Below information:

 Supplier.
 Challan bills.
 Gate entry
  Store entry.
 Description.
 No of cartons.
 Quantity.
 Remark and send to account department along with Bill.

GATE PASS: Two Type

1. RGP- Returnable Gate pass- if the stock

have to factory-in.
2. NRGP- Non Returnable Gate pass- if the
stocks have not to factory-in.

LOGISTIC AND DISPATCH DEPARTMENT.

Mr. Vipin Huria is HOD and 2 persons are there to assist him.

Process:

 Goods from ADC, Lamination and WADS.

 Dispatch planning.
 Informing to carrier.
 Invoice Generation.
 Dispatch.

Checking: Goods should be as per invoice and Description.

Final Dispatch: As per instruction from Sales Department (i.e. any Account no
of DHL, TNT etc.)

*************
 PPC DEPARTMENT- Mr. Amit.

Role and Responsibility:

 To check all inputs as per sale order.

 Arrange all the Raw Material.
 Internal Planning.
 Production planning as per capacity and availability of all the inputs.
 Target of Manufacturing of a commercial supply within 7 days.

*************
 WIDE WEB PRINTING DEPARTMENT

Mr. Mohan is Plant Head. Mr. Dharmendra Sirohi (GET) is assisting him.

Wide web Process:

 Arrangement of Raw Material.

 Embossing on13µ clear pet.
 Metalizing.
 Slitting.
 Packing.
 Dispatch.

Raw Material:

 Embossing-13µ PET (1µ inside quoted).

 VHB-3M
 SHIM (400 mm approx and 45-55µ)

Product Application:

-Wide web-Packaging.

Machine Process-

1). Wide web Embossing.

 Thermia B oil for heating.

 Pre-Heat Roller.
 SHIM Roller.
 Pressure Roller.
 Rubber Roller & Chiller Roller.
2). Matelizer:

 Vacuums created in Chamber.

 All Wire melting on a defined temp.
 Vaporized.
 Chillers.
 Rewind.
3).Slitting:

 Cutting as per Client requirement.

 SHRINK SLEEV

Process:

 Printing on PVC.
 Slitting.
 Tubing.
 Inspection.
 Cutting.
 Packing.
 Dispatch.

Raw material:

Only PVC. Shrink Sleeves Made of PVC only.

Machine Operation:

Gravure Printing Machine-2:

1). 8 colors (manual)

2). 10 colors (automatic).

Raw Material:

 PVC
 Colors.
 Hologram.
 Adhesive.
 Printing cylinders.
Inspection:

 Printing
 Tube
 Holography (transfer).
 Leakage.
 Joints.
Cutting:

Cutting as per Size and perforation (for tear purpose……..).

Preforming:

As per requirement of client, Neck molding.

Material Used for Shrink Sleeves:

1). Balloon PVC –Normal (Maximum).

2). Cast PVC- Two times costly than Balloon PVC (as per customer
requirement.) More Shrinks, More Clarity.

3).Shrink PET (rare).

POUCHING

Process:

 Polyester-PET
 Printing.
 Lamination with poly.
 Slitting.
 Pouching.
 Dispatch.

Types of Pouch: Two types:

1. Laminated pouch.

2. Paper Pouch.

Construction of Laminated Pouch-3 layer:

I. Poly –inside.
II. Holography.
III. PET- Printed
In case of two layer of pouch there is only printed PET and poly.
Construction of Paper Pouch:
 Paper.
 Aluminium (7µ).
 Chemical Coating.

Type of color used in printing- solvent based.

Type of adhesive used in lamination:

1) Water Based- Paper Lamination

2) Solvent Based- PET
Material Used for Pouch:

1) PET- Clear PET

2) Poly.
3) Paper.

**************************
 NOIDA PLANT-W-44 Label Division.

Flexo Printing: Two types:

1. UV printing-Glossy-more Costly.

2. Water Based –Without Glossy-Less Cost.

Two Machines:

1. GIDUE – 370 MM - 8 colors

2. GALLUS.- 280 MM - 9 colors
Major Raw Material:

 Paper
 Ink
 Die
 Plates
 Hologram

Printable With/ Without Adhesive Material:

 Paper-110,210,170,250GSM
a. Holographic
b. Without Holographic
 Film
a. Holographic
b. Without Holographic
 Tag
a. Holographic
b. Without Holographic
 Security.
INK:

 UV Based (UV lamp).

 Water based (IR lamp, Hot air).
 Solvent Based (Hot Air).
 Heat Sensitive (once we rub this will disappear @35ºc).
 Color Changing.
 Florescent Green (UV Glow-UV light)
 Invisible (UV Light).
 Copy wide (Micro Lines can be seen after photocopy).
  Scratchable hologram.
 Tagent Ink- can be checked by Tagent reader.

PAPER:

 Mirror Coat-80 GSM- Oil & Pharma, certificate etc.

 Silver Metalized-60 GSM-Liquor, Bear.
 Cromo Paper 110/170 GSM-Lungis etc
 Cromo Paper 75 GSM-general Paper.
 Laser paper-80GSM Greenish and light, Maximum for certificates.
 Art paper-170 GSM- Both side Glossy, both side printable, warranty
card.
 Art paper-215 GSM-Tags, Rice etc.
 Tyvek- 45 GSM-Picture is not recommended, used where the labels are
stitches.
 Non-top coted-160 GSM, Thermal paper, Carbon paper.
 Opaque PET- 152 GSM-Filmic Cant be tear.
 Silver Metallic filmic-130 GSM-Tearable, Non-tearable.
 Maplitho label-160 GSM- Ink Observation, High security, rough Surface.
 Board paper-250 GSM- Tag.
 Cromo paper -161- Maximum Use normally.
 P-85 is little tight but tearable.
 Clear on clear is non tearable.
 Mirror-Coat-161 same as cromo.
 HIGH SECURITY PAPERS:
o Filmic Void Temper proof- for seal in warranty.
o Filmic self destructive bearable vinyl self adhesive -120GSM –
bearable like rubber, used in meter seal.
o Ultra Destructive vinyl- 120 GSM. It is tearable like egg cover.
o Fomtac Vinyl -240 GSM- One time use. After tear it left one copy
of it.
o Above all there vinyl papers are passed in alcoholic test and at
certain high temp it will be destroy.
o Dual Paper-Invisible Fibers, Two colors- Red & yellow for
cigarettes.
o Dall papers- If we check in UV Light it doesn’t appear bright, for
cigarettes
o High Bright-It is the same as above.
PROCESS:

 Order.
 Raw material arrangements.
 Production Planning.
 Inspection.
 Finishing activities- Roll, sheet, cuts.
 Numbering if required.
 Packing.
 Random QC check.
 Dispatch.

Detailed Printing process:

 Printing plate checking as per given artwork.

 Choosing printing cylinders as per mater data.
 Plate mounting on mounting machine.
 Loading of Ink in printing tray.
 Registration setting.
 Magnet Cylinder loading.
 Die Mounting.
 Shade Machine as per approved shade card.
 Text checking as per approved artwork.
 Printing production.
 QC Check each and every roll after printing.

Things to Remember during a new discussion of any order of Labels:

o Width.
o Height.
o Holography-Specification- running or Registered.
o Holography apply form (Direction-Vertical or Horizontal).
o Colors (how many)
o Glossy .?- Varnish- nothing can be printed, Aqua- can be printed,
Melt varnish- Little rough.
o Plain.?
o Lamination.
o Special feature.
o Numbering
o Barcode.
o Quantity.
 o Substrate.
o Raw Material Specification.
o Supply form (Direction)
o No of Labels in a roll or bunch.

Things to Remember during a new discussion of any order of Holograms:

o Supply form-Sheet/Spool/strip.
o Direction.
o Size of Hologram in mm.
o In case of HSF strip width etc. Machine specification.
o Strip type (with or without release paper).
o Design-Running or Registered.
o Quantity.
o Substrate.
o Nature of substrate.
o Substrate surface- Plain/smooth/rough/laminated/painted.
o Hologram positioning on surface-Flat/Round/Bend at 90 degree.
o Shape of Hologram-square/rectangle/circle/ellipse/Other.
o Corner-Sharp/Rounded/any other.
o Foil color-HIL standard or another & thickness.
o Spool O.D.
o Core I.D.
o Core type (Plastic/Paper).
o Method of Application-manual/Auto.
o Temper property-CTS//NTS/Text temper/Customized Pattern.
o Numbering-Laser/inkjet/UV/Thermal-Digits or Alphabets.
o MOST IMPORTANT-Substrate.

Suggestion for Production Department:

All packing material should be printed in Holostik Brand i.e. Core, cartons,
tapes etc.

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