Manufacturing Flexible Packaging

1st Edition

Materials, Machinery, and Techniques

Authors: Thomas Dunn
Hardcover ISBN: 9780323264365
eBook ISBN: 9780323265058
Imprint: William Andrew
Published Date: 4th September 2014
Page Count: 304
Tax/VAT will be calculated at check-out
Compatible Not compatible
VitalSource PC, Mac, iPhone & iPad Amazon Kindle eReader
ePub & PDF Apple & PC desktop. Mobile devices (Apple & Android) Amazon Kindle eReader
Mobi Amazon Kindle eReader Anything else

Institutional Access

Table of Contents

  • Introduction

    • Background
    • Reference
  • 1. Basics of Web Processes

    • Web Tension
    • Web Winding
    • Cross-Web Variation
    • Web Dimensional Analysis
  • 2. Rotogravure Printing

    • Gravure Process
    • Gravure Cylinders
    • Halftone Image Reproduction
    • Ink Metering
    • Gravure Process Innovation
    • Cylinder Cost and Cycle Time
    • Reference
  • 3. Flexographic Printing

    • The Flexo Process
    • Reference
  • 4. Adhesive Lamination

    • Adhesive Laminating Process
    • Adhesive Lamination Strength
    • Other Coating Processes
    • Adhesive Laminating Innovation
    • Reference
  • 5. Extrusion Lamination and Coating

    • Extrusion Laminating Process
    • Extrusion Coating Process
    • Extrusion Laminating Innovation
    • References
  • 6. Finishing and Slitting

    • Communicating Slit Roll Requirements
    • Slitting Options
    • Rewind Options
    • References
  • 7. In-Line Processes

    • Equipment Requirements
    • Operational Considerations
    • Success Criteria
  • 8. OEE Effectiveness

    • Overall Equipment Effectiveness
    • Availability
    • Performance
    • Quality
    • OEE Calculation
    • References
  • 9. Efficiency and Cost Accounting

    • Efficiency
    • Cost Accounting
    • References
  • 10. Basics of Control Systems

    • Distributed Control Systems
    • Data Inputs
    • Process Feedback
    • References
  • 11. Rotogravure Presses

    • Press Components
  • 12. Flexographic Presses

    • Press Components
    • Reference
  • 13. Adhesive Laminators

    • Dry Bond Laminators
    • Solventless Laminators
    • Online Coating Measuremen


Efficiently and profitably delivering quality flexible packaging to the marketplace requires designing and manufacturing products that are both "fit-to-use" and "fit-to-make". The engineering function in a flexible packaging enterprise must attend to these dual design challenges.

Flexible Packaging discusses the basic processes used to manufacture flexible packaging products, including rotogravure printing, flexographic printing, adhesive lamination, extrusion lamination/coating; and finishing/slitting. These processes are then related to the machines used to practice them, emphasising the basics of machines’ control systems , and options to minimize wasted time and materials between production jobs.

Raw materials are also considered, including the three basic forms: Rollstock (paper, foil, plastic films); Resin; and Wets (inks, varnishes, primers). Guidance is provided on both material selection, and on adding value through enhancement or modification of the materials’ physical features.

A ‘measures’ section covers both primary material features – such as tensile, elongation, modulus and elastic and plastic regions – and secondary quality characteristics such as seal and bond strengths, coefficient of friction, oxygen barrier and moisture vapour barrier.

Key Features

  • Helps engineers improve existing raw material selection and manufacturing processes for manufacturing functional flexible packaging materials.
  • Covers all aspects of delivering high value packaging to the customer – from the raw materials, to the methods of processing them, the machines used to do it, and the measures required to gauge the characteristics of the product.
  • Helps engineers to minimize waste and unproductive time in production.


Engineers, product designers and materials scientists in the packaging industry, particularly key end use sectors such as food and medical.


No. of pages:
© William Andrew 2015
William Andrew
eBook ISBN:
Hardcover ISBN:

About the Authors

Thomas Dunn Author

Managing Director, Flexpacknology LLC

Affiliations and Expertise

Flexpacknology LLC