Technology of manufacture
Materials preparation
We produce tubes out of ABL and PBL laminates by the following manufacturers as HUHTAMAKI, ALCAN and PACTIV.
The department of preprinting preparations works on implementation of the most courageous design developments of our clients. After preparation of make-up pages and colour separation is carried out, the photopolymeric typographic plates are produced.
After a careful check up of the readiness of the circulation for printing (from check of readiness of the forms as well as paint) ready typographic plates are transferred to the production where they are mounted on printed bulwarks using such specialized machinery as Speedmounter Narrow by FlexTech company. Thanks to the implemented computer system, all necessary information on circulation in on-line regiment goes to the printer. It ensures on-rolled registration of commodity and intermediate identification mark of rollers.
Printed machinery
Borrowing experience from the leading world manufacturers working with P&G and Colgate, we purchase only high quality printed machinery:
- printing machine knots ensure ideal colour matching and secure the complete lack of any stretch of laminate material;
- specialized surface refining devices of the laminate by TEKNEK company ensure lack of any dust and microparticles of the polyethylene used in-process;
- the machinery on material processing by corona discharge allows to achieve good adhesion of colors;
- the printing machine is equipped by three tension control devices of tube laminate;
- specially constructed extension of the printing machine and installation of 2 powerful finishing lacquer dryers allows to achieve in glossy varnish of the maximum gloss and secures flat varnish thorough drying.
Quality control
For each roll of material geometrical parameters as well as adhesion of lacquer-ink materials by means of spectrophotometers, densitometers and GTI MiniMatcher machineries by company GTI Graphic Technolology are checked.
After the printing machine the rolls go onto rewinding machinery by companies ROTOFLEX (Canada) and AZTECH MACHINERY (USA). QA controllers of a printed web do not less than three control shears from the miscellaneous part of the roll of laminate for testing. The information on each shear is skidded in special identification tags "Check measurements".
After finishing quality control of the finished products, laminate rolls are weighed, packaged and by means of net operated computer system are labelled according to requests of our customers.
Production of tubes
The tubes produced by our company meet the highest requests of quality and are fabricated on modern state-of-the-art machinery by AISA and PSG.
For production of tubes only high-quality components of various range of colors and size types (shoulders and caps) of domestic and foreign production are used. Tubes can be produced from laminates ABL (Aluminium Barrier Layer) and PBL (Plastic Barrier Layer) of various width. The raw materials, components for tubes production go through a compulsory procedure of an incoming inspection of quality before distribution in production.
Technological cycle of tube production on AISA machinery consists of the following phases.
- Preparation of the web with edge trimming.
- Laminate welding into the endless sleeve.
- Cutting the sleeve into the tubes of required length.
- Welding of a shoulder to a tube.
- Top-sealing.
- Capping the tube.
All processes are executed in an automode and inspected by the processor of machinery with self-acting rejection of the tubes mismatching the preset parameters. Besides that the random sampling during the manufacturing process is done and 100% monitoring on external appearance is implemented.
The work cycle of production of tubes PSG machinery consists of the following phases.
- Laminate preparation (an edge cutting if necessary).
- Laminate cutting on reprints of the preset length.
- Manufacture of a tube body.
- Capping.
For the purpose of product preservation the tube port can be top-sealed by protective membrane.
Our company is aimed to improve the quality and competitiveness of produced commodity by means of constant perfecting of an operating procedure, usage of high quality materials and learning of market demands of plastic packaging.
