Installation Case Study

ORORA PACKAGING
BROOKLYN SITE ECO-CHEM PRODUCT INSTALL

Current Status for Print Unit Wash Up on Case Makers

The case makers currently use the automatic system supplied with the OEM equipment for print unit wash up using water for wash up only. Blade clean cleaning product was sprayed on manually.

Current Status for Stereo Wash Up on Case Makers

We currently run a ring main line to our case makers which is supplied via a pumping station located in our ink mixing plant.
This pumping station dilutes the Blade clean product with water at a ratio of 10:1.
In turn this pre mixed product is always at the ready at the stereo wash bay hand guns.
This unit has been not used for some years.

Scope of works

To install Eco-chem product to case makers print unit wash up system which includes the following:
Hybrid 12000
Jumbo Cl 5055
Emba 170
Texo 165
Martin DRO
Martin 924.
Also to re-commissioned Stereo Wash Bay system.

Trial

Brooklyn was approached in June 2009 to trial the use of Eco-chem product for our stereo wash bays and to also install Eco-chem product to the Texo print unit wash up system (four colour machine- black ink predominantly used).
We firstly recommissioned the Stereo Wash System by installing appropriate hand guns at the wash bays and ensuring the pumping station functioned correctly. We installed the Eco-chem product inline with the pumping station which automatically dilutes the Eco-chem product with water at a ratio of 50:1.
This pre mixed product is always at the ready for the stereo wash bay hand guns and in future for the case makers wash cycle as this product is fed via a ring main pipework .

The Texo Print Unit Wash up with Eco-chem product was set up Print Unit No 4 ( predominantly black ink used).
Firstly we had print unit 3 & 4 Anilox rolls cleaned (soda blasted) as a starting reference to ensure both anilox rolls were clean.
We engaged Laserlife to conduct a cell depth analysis on both anilox rolls before and after the use of Eco-chem product.
We found that after 1 months use of Eco-chem product the cell analysis had improved significantly on print unit No 4 ( eco-chem system installed) and on print unit No 3 no significant improvement was made with the current wash cycle in place. Both cell depth and volume had increased on Print Unit No 4. (see attached data). Below is AnaCam Analysis data.

TEST DATE PRINT UNIT No CELL VOLUME CELL DEPTH SCREEN COUNT CELL WALL CELL OPENING SCREEN ANGLE ECOCHEM PRODUCT USED
02-06-09 3 10.9 BCM 72 um 250 lpi 0 0 60 deg
02-07-09 3 10.4 BCM 63 um 250 lpi 0 0 60 deg NO
02-06-09 4 9.0 BCM 47 um 250 lpi 0 0 60 deg
02-07-09 4 10.7 BCM 69 um 250 lpi 0 0 60 deg YES

We had also found that not only did the anilox rolls improve but also the cleanliness of the print units had also improved significantly.

Case Makers Print Unit Wash Modifications

With the trial considered a success on the Texo, a project to install all Case Makers wash up system with the Eco-chem product had begun.
Find in brief details below what was done to each Case Maker.

Texo

  • Tap into stereo wash system line to provide soap to print units
  • Modify valving to accommodate the new soap line
  • Modify the opening and closing times of the valving system from the PLC
  • Utilized existing PLC on machine to drive additional soap system

Jumbo

  • Tap into stereo wash system line to provide soap to print units
  • Modify valving to accommodate the new soap line
  • Modify the opening and closing times of the valving system from the PLC
  • Utilize new control PLC to incorporate the opening and closing of valves for Eco-chem product. More effective than trying to access machines existing PLC

Martin DRO

  • Tap into stereo wash system line to provide soap to print units
  • Modify valving to accommodate the new soap line
  • Modify the opening and closing times of the valving system from the PLCUtilize new control PLC to incorporate the opening and closing of valves for Eco-chem product. More effective than trying to access machines existing PLC

Martin 924

  • Tap into stereo wash system line to provide soap to print units
  • Modify valving to accommodate the new soap line
  • Modify the opening and closing times of the valving system from the PLC
  • Utilize new control PLC to incorporate the opening and closing of valves for Eco-chem product. More effective than trying to access machines existing PLC

Emba

  • Tap into stereo wash system line to provide soap to print units
  • Modify valving to accommodate the new soap line
  • Modify the opening and closing times of the valving system from the PLC
  • Utilize new control PLC to incorporate the opening and closing of valves for Eco-chem product. More effective than trying to access machines existing PLC

Hybrid

  • Tap into stereo wash system line to provide soap to print units
  • Modify valving to accommodate the new soap line
  • Modify the opening and closing times of the valving system from the PLC
  • Utilize new control PLC to incorporate the opening and closing of valves for Eco-chem product. More effective than trying to access machines existing PLC

Final Conclusions

  • Improved anilox roll cleanliness and quality and reduce / eliminate soda blast cleaning.
  • Improved ink chamber cleaning which increases the life of ink chambers, seals and sprays.
  • Improve cleanliness of ink pumps which reduces pump blockages and wear due to build up.
  • Reduce cleaning time with shorter wash cycles.
  • Reduce water consumption with shorter wash cycles.
  • Cost savings from the improvements above.