VIVEK SINGH BASC IV

1 Q. Write a detailed note on coating colour preparation giving detail of all additive and mention importance of
order of addition and their function

Ans: - coating colour can be prepared

 Order of addition and their function

Water Dispersent pigment Binder Co-binder

Insolubilizer Optical whitening agent Lubricant

[Link] and Dispersants

Example – Polyphosphates, Lignosulfonates, Silicates
Function
- Dispersent are low molecular weight material that are absorbed to pigment surface proving enhanced
stability by keeping the particle associating to each other
- It is used to disperse pigment to achieve minimum viscosity at high speed disperse rate

2. Pigments
Example - Clay, PCC, TiO2, Plastic Pigments (Polystyrene)
Function –fill the void and low spots of sheet surface to create smooth surface and provides a light
scattering surface.

Importance of addition: these are added to provide maximum time for dispersion because poor dispersion leads
to problems such as blade scratches, excess rejects at screens, rheological fluctuations, and runnability
disturbances at the coaters.

Reason for adding dispersant first and second pigment -

1. When the minerals (pigments) are added in water they develop surface charges and unlike charges attract
themselves and result in aggregation and result in high the viscosity.
2. These are added to provide maximum time for dispersion because poor dispersion leads to problems such as
blade scratches, excess rejects at screens, rheological fluctuations, and runnability disturbances at the coaters.
3. Chemical dispersant are water soluble and ionize readily, so when pigment are added to water the anionic portion
goes to particle surface and there is balance of charge which result in particle separation and reduces the viscosity
of solution.
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3. Binders
Function –
- Binds pigment particles together.
- Binds Coating to paper.
- Reinforces the base sheet.

Example:-
- Natural (starch and protein)
-Synthetic (styrene butadiene, polyvinyl acetate, polyvinyl alcohol, styrene-acrylic, vinyl-acrylic)

Co-binder
Function - Affect the Rheology and water retention properties of coating colour
Example –
i. Starch
- Advantages are low cost, water retention, runnability, and stiffness
ii. Protein
- Advantages are glue ability, water retention, run ability, and blocking.

4. Lubricants/plasticizer (calcium stearate most common)

Example – Stearate, Wax emulsions
Function - Improves the flexibility of coating films and this lead to improve blade coater runnability, give release
properties to the sheet, reduce dusting, reduce picking and improve gloss.
.

5. Rheology Modifier/thickener
Example: - (CMC, HEC, polyacrylates, sodium alginate)
Function – Controls coating viscosity and water retention properties. This improve coater runnability, printing &
convertibility.
.

6. Optical Brightener
Example:-OBA
Function- it will provide attractive colour and brightness

7. Cross linkers /Insolubilizer

Example –urea formaldehyde, glyoxyl
Function –
- The water soluble binder tent to lose their binding power when it come in contact with water and get
dissolved. The water sensitivity of binder can be decrease by cross linking the soluble binder together with
Insolubilizer by building hydroxyl and carbonyl group around bonder.

8. Anti-Foam Agents
Example:-
Function
- Controls foam problems.
- Eliminates air bubbles.
VIVEK SINGH BASC IV

2. Q. Explain construction and working of corrugating machine giving detail of raw material
requirement and types of flutes?
Raw material

1. Straw,Kraft, waste paper or semi chemical pulp

2. Bleached liners are used in advertisement field due to attractive printing quality
 Qualities needed for liners are
1. Toughness and durability
2. Weights of 42 to 90 lb/1000 square foot
3. Bursting strength 100 to 150
 Requirements for good Corrugating medium are
1. High degree of stiffness
2. Must bend well under high moisture
3. Must have uniform caliper and uniform moisture content
4. Corrugating medium is about 0.009 inch in caliper
Construction- Corrugating machine consists of a set of Corrugating rolls, glue applicator rolls, Finger bar and a hot
plate section
Major adhesives -used for corrugation are sodium silicate and starch

Working

 Corrugating medium is preconditioned before entering Corrugating rolls and further heated at the steam
heated Corrugating rolls
 Corrugating rolls are also heated using steam of 130 to 175 psi to produce surface temperature of about 320
to 340o F
 Moist heat is supplied by steaming to controls the plastic properties of the corrugating medium during
corrugation
 Treatment of corrugating medium with moist heat makes paper soft and pliable to produce uniform
corrugations or flutings
 It also prevents sticking of the paper to the corrugating rolls
 Liners are preheated by passing over steam heated pre heater rolls(about 36” diameter)
 Heating is determined by the amount of wrap of paper around the roll
 On leaving the corrugating rolls the corrugated medium fluffs out to meet a glue applicator roll
 Applicator roll applies adhesive to one side of the paper
 Amount of pluffing out is controlled by long metal strips
 Proper setting of fingers required to prevent damage to flutes and poor adhesive application
 Immediately after adhesive application first liner is brought in to contact with the glued side and high
pressure is applied for a fraction of second to set the adhesive
 The board obtained is called single face
 For double faced manufacture it moves to an elevator and collects in folds to provide continuous feed for
double backer glue station
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 Adhesive applied on to the flutes on the other side of corrugating medium and second liner applied in 5 to
30 seconds
 Combined board enters hot plate section and held against platens by means of heavy belts
 Setting of the adhesive on the double back side takes place at this point and excess moisture is driven from
the board
 At the end the board is slit and flap scored
Types of flutes
A-Flutes, B-flutes, C-flutes, E-flutes, F-flutes

3Q. how are papers used for printing classified?

Ans: - printing paper are classified into two main category i.e. mechanical paper and wood free paper
1. These are again sub divided as shown
I. Mechanical paper: - Made from mechanical pulp and also from CTMP and TMP
A. Uncoated mechanical paper: - again classified into following
i. News print
ii. Machine finished: - classified as
a) Machine finished mechanical (used for general printing)
Ex: - MF offset
GSM 70-90
Brightness 60-76%
smoothness 2.2-3

b. telephone directory (grammage =27-40gsm)

c. bulk mechanical (printing book)
Ex: - paper bags
GSM 45-100
Bulk 1.8-2.5 cm2/g

III. Supercalendered paper: - classified as

- Printability depend on filler level and super calendaring (usually soft calendaring)
- Used for gravure printing
a) SC-A (publication quality super calendar)

b) SC-B (lower filler content and used for 4 colour printing)

SC-A SC-B

Filler content 18-33 8-16

ISO brightness 66-76 60-68

Hunter gloss 30-53 25-35

VIVEK SINGH BASC IV

Smoothness 1.9-3.0 0.5-1.6 micrometer

c) SC-C (has lower hunter gloss)

d) Electrostatic Assist (lower smoothness than usual paper)
e) SC offset
- Developed for offset lithographic printing
f) Super treated paper STP
- Allow to use high tack ink
- Compete better with light weight paper
B. Coated mechanical paper

i. film coated offset-FCO- coated by film size press

ii. Pigmented paper
iii. Machine finished coated paper –MFC (used for heat set web offset printing)
iv. Light weight coated paper- (for offset and gravure for magazine)
iv. Ultra light weight coated paper - (used for catalogue)
vi. Medium weight coated paper - (super calendar paper)
vii. High weight coated paper -(more chemical pulp)
FCO Pigmented paper MFC LWC MWC HWC

Grammage (GSM) 30-80 50-85 50-100 - 65-80 80-120

ISO brightness% 71-72 73-76 70-78 65-76 72-80 81-91

Hunter gloss % - 23-30 15-30 40-70 55-70 -

Smoothness (micrometer) 2.5-3 1.9-3 0.5-1.6 0.5-1.6 -

2. Wood free paper – free from mechanical pulp

A. uncoated wood free paper
I. thin printing paper
- Higher filler ,good opacity
- Used for Reference book ,bible etc
ii. Security paper
- Cheques, certificate ,passport etc
iii. Business grade – these are again classified as
a) Photocopy paper
- (smoothness, roughness, good stiffness , no curl, good brightness)
b) Laser printing paper
- (strength & surface property, good printability)
c) Bible printing paper
- (good opacity, tensile strength wax pick, gloss)
d) Cut sheets paper
e) Typing paper
- Bond paper ,bank paper, manifold
f) Continuous stationary
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g) Business form
– made from uncoated wood free and mechanical paper
f) Off set paper-
- used in office printing paper
h) Duplicating paper-
- made from mainly mechanical to wood free used with stencil duplicator
B. Coated wood free paper:
i. coated one side
a) Label b) poster c) chrome d) wallpaper
ii. Coated two side
a) cast coated b)other wood free coated

4 Q. Explain gravure and screen printing process with diagram giving details of paper requirement and their
application? Print

Paper

Ans
Impression
Cylinder
1. Gravure printing
Paper requirement
- Smooth & level (PPS-10, no curl) Gravure
Cylinder
- Compressible Gravure
Cylinder
- Free of surface debris
- Soft coating Doctor

- Ink holdout Blade

- Uniform GSM ,moisture ,caliper ,formation

- Water absorption and two sidedness plus optical property Ink Pan

Process

 Gravure is major exponent of intaglio process.

 It uses cylinder and has an advantage that it can change the printing length by changing the cylinder..
 Because the cylinder is expensive to produce it has been used for long print run.
 In gravure printing, the image is engraved onto cylinder and this is partially immersed into pan
containing the ink
 As the cylinder rotates it draws excess onto the surface and into the cell
 The doctor blade scrape the cylinder to remove excess before it make contact to paper surface
 Next the substrate gets sandwiched between impression roll and gravure cylinder and due to this ink gets
transferred from gravure cylinder to substrate.
 The purpose of impression cylinder is to apply force ,ensuring that entire substrate is brought in contact
with gravure roll
 Then the inked substrate goes through dryer for drying
Application:-

- Currency
- Bond certificate
- Stamps
- Greeting card
- Magazines
- Business form

2. Screen printing
Definition: - screen printing is process of transferring a stenciled design onto a flat surface using a mesh screen ,ink
and squeeze
Paper requirement
VIVEK SINGH BASC IV

- Flatness of the sheet to prevent the ink oozing out through edge of plate

- It should have Basic proper of paper like uniform GSM ,caliper , smoothness and softness, opacity, gloss,
surface strength

Process:

The process of screen printing consist of five prerequisites to ensure identically reproducible thick film, these are as
follow
- Suitable printing medium
- Mesh screen with an embedded stencil design
- Substrate to print upon
- Flexible and resilient squeegee
- Secure base to prevent moment of substrate within the process
- Steps involved in printing

Application

Used for printing on

- textile, wall magazine, wall coverings
- plastic bottle and other objects like irregular or unusual shapes

Q. Describe the process of manufacture lamination paper with requirement?

Ans. Steps of lamination

I. Applying the adhesive
II. Combining the plies
III. Setting the adhesive
Applying the adhesive

 Uniformly distribution and accurately controlled film of adhesive important

 Success of entire process depends on this step
 Too much or too little or uneven application leads to poor, spotty or no bonds
 Applied widely by roll coater, calendaring or sizing
 Extrusion coating is accurate but complex way of application and eliminates outer environmental
influences like drying, cooling, contamination etc.
 Spray application used in packaging operation
 Dip, flood or tub sizing may be used
 Minimum quantity of adhesive that will wet and fill the voids must be used
Combining the plies

 All laminating processes involve period of open time before joining substrates
 May be minutes, hours or days but fast converting operations limit to seconds
 Adhesive begins to set during open time
 Long distance between glue application and pressing (long time) provides setting & cooling prior to pressing
 But long time may result in more penetration or spotty wetting of opposite substrate
 Pressure is required to join substrates and manner of application, amount of pressure and duration of force
affect intimacy of contact
 High pressure spreads adhesive in to thin film or force it in to substrate
 Too less pressure results in poor bonding
 Rolls are commonly used with controlled nip pressure and angle of contact
VIVEK SINGH BASC IV

Setting the adhesive

 Final step in forming laminate includes drying, cooling and curing of adhesive
 It is necessary to dry, cool or heat the laminate to speed up Setting
Drying –

 water or organic solvent from laminates is done by passing web through heated chamber over heated rolls
 Cheap low solid adhesive needs more energy than high solid adhesive with little or no drying
Cooling –

 Laminates combined with hot melt, heat sealed or wax

 Laminated need cooling for rapid setting
 Done by passing web over cooled or chilled rolls
 Though the cooling costs are less the initial melting cost of these adhesives makes them expensive
Curing –
- Setting of polymerized adhesive needs heating laminate as chemical reaction at high temperature is rapid
- Along with function of holding the plies other functions of adhesive are
 Insensitivity to water
 Control of curl
 Complete re pulp ability
 Greater opacity
 Increased stiffness
BASE PAPER

Any type – Unbleached and bleached Kraft, tissue, glassine, chip board, solid news, bleached sulfite
Selection – desired properties
 Aluminum foil – for packaging and industrial uses
 Lead and tin – lower properties
High strength, increased impermeability, good stability – cellophane, poly ethylene, polyester,
 Less commonly used – polystyrene, poly urethane, polypropylene, nylon,
Cloth and fabrics –
 Ordinary uses - nylon, cotton
 High strength, durability, tough packing – fiber glass, burlap, jute

5 Q. a

To fill a deckle (trimmed of 188cm) a real of 80gsm substance is cut into portion of 2x56cms and 1x76cms to
obtain paper of two different size of 56 x 91cm and 76 x102 cm. find out approximate number of sheet of two size
obtained by cutting the full reel into sheet the weight of reel being 376 kg .portion of deckle utilized for the sizes
56 x 91cm and 76 x 102 cm are 2x56/188 respectively

Ans. Total weight of the reel =376 kg

Total deckle of the reel =188cm

Substance wt of paper = 80GSM

First real deckle = 56cm First size of paper = 56x91cm

Second real deckle = 56cm Second sized of paper = 76 x102cm
Third real deckle = 76cm

Total length of paper in reel = 376 x 105

188 x 80
VIVEK SINGH BASC IV

= 2500 m

Weight of 56 cm width reel= L X CX 9 =2500 X 56 X80 = 112 Kg

105 105

Weight of 56 cm width reel =112 kg

Weight of 76cm width reel = L X CX 9 =2500 X 76 X80 = 152 Kg

105 105

Number of sheet in first reel of width 56cms = weight in kg x 107 = 112 X107 = 2747 Sheet
GSM x l x b 80 X56 X91

Number of sheet in first reel of width 56cms = weight in kg x 107 = 112 X107 = 2747 Sheet
GSM x l x b 80 X56 X91

Number of sheet in first reel of width 76cms = weight in kg x 107 = 152 X107 = 2450 Sheet
GSM x l x b 80 X76 X102

The total number of sheet of size 56 x91 cm is 5494

The total number of sheet of size 56 x91 cm is 2450

b)
Calculate coat weight for 100GSM paper with 25MT production using following data
Starch -500kg with 12% moisture ,pigment 1- 62 kg with moisture 15% pigment 2 – 64 kg with 14% moisture ,SBR -62
kg with 52% moisture ,OBA -125 Kg with 68 % moisture .
Ans.
Component Moisture Dry solids in kg Solid as such
Starch 12 500 568.18 kg
Pigment 1 15 62 72.92 kg
Pigment 2 14 64 74.41 kg
SBR 52 62 129.16 kg
OBA 68 125 390.625 kg
Total =813 kg Total =1235.295 kg

1. Starch as such = (100 xOD wt)/ (100- M %) = (100 x 500)/ (100-12) =568.18 kg
2. Pigment 1 as such = (100 xOD wt)/ (100- M %) = (100 x 62)/ (100-15) = 72.92 kg
3. Pigment 2 as such = (100 xOD wt)/ (100- M %) = (100 x 64)/ (100-14) = 74.41 kg
4. SBR as such = (100 xOD wt)/ (100- M %) = (100 x 62)/ (100-52) = 129.16 kg
5. OBA as such = (100 xOD wt)/ (100- M %) = (100 x 125)/ (100-68) = 390.625 kg

Percentage solid by weight = (wt of dry pigment x 100)/ (wt of dry pigment + water)
70% = (147.33 x100)/ (147.33 + x)
X = 210.4 -147.33 = 63.14 kg

Coating solution requirement MT = (Given coat weight (g/m2) x total weight of paper T)/ (GSM of paper)

Coat weight g/m2 = (coating solution x GSM)/ (total weight of paper T)

= (1.24 x 100) / (25)
= 4.8 g/m2
Q. Write a note on packaging law and regulation for food products?
Ans
 The link between food packaging and consumer protection is of high significance.
VIVEK SINGH BASC IV

 To safeguard the interests of the consumer and the society at large, Packaging Laws and Regulations have
been introduced by the Government.
 The Packaging Laws and Regulations for food products are mainly covered under:
 Agricultural Produce (Grading and Marketing) Act 1937
 Prevention of Food Adulteration Act 1954 and the Prevention of Food Adulteration Rules, 1955
 Essential Commodities Act, 1955
 The Fruit Products Order, 1955 (FPO)
 Export (Quality Control and Inspection) Act, 1963
 Codex Standard (CAC) 1964 (not a law)
 De-oiled Meal and Edible Flour Control Order 1967.
 The Meat Food Products Order, 1973 (MFPO)
 The Standards of Weights and Measures Act, 1976 and the Standards of Weights and Measures
(Packaged Commodities) Rules, 1977 (SWMA).
 Mandatory inspection SWMA rules, 1977.
 Bureau of Indian Standards, 1986
 The Edible Oil Packaging Order, 1998
 Ministry of Consumer Affairs HACCP 9000 certification.
 Ministry of Health and Family Welfare Protects Consumer against inferior quality and adulteration
 Endorsement by WTO under SPS and TBT.
 Packed Foodstuffs must adhere to quality declaration 417
 The AGMARK Rules
Food Packaging Regulations
 The safety of all materials used for packaging foods is controlled under Division 23 of the Food and Drugs Act
and Regulations, Section B.23.001 of which prohibits the sale of foods in packages that may impart harmful
substances to their contents.
 This regulation puts the onus clearly on the food seller (manufacturer, distributor, etc.) to ensure that any
packaging material that is used in the sale of food products will meet that requirement.
1. Premarket Assessments
 Because of the general nature of this requirement, and in the absence of positive lists delineating permitted
ingredients, packaging materials intended for use with foods may be submitted voluntarily to the Food
Directorate (FD) for a premarket assessment of their chemical safety in relation to Section B.23.001.
 This applies to any type of material, whether it is in the form of a finished product such as a laminated film, a
container, etc. or a formulated product such as a plastic resin, a colour concentrate, etc.
 In addition, suppliers of single additives like antioxidants, ultra violet absorbers, etc. may also independently
request letters of opinion for their own products before selling them to formulators or converters.
2. Letters of No Objection
 Letters expressing favorable opinions are called "no objection letters' and can be used by the recipients to
assure their prospective customers that the products they are selling have been evaluated by the Food
Directorate and deemed acceptable, from a chemical safety standpoint, for use in specified food packaging
applications.
 However, it is important to note that such letters do not constitute approvals in a legal sense and do not
relieve the food sellers of their responsibilities under Section B.23.001 of the Food and Drug Regulations.
3. Duration of No Objection Status
 A letter of no objection has no expiry date. It is considered valid as long as the composition and intended use
of the material remain as described in the original submission.
 It is the responsibility of the manufacturer to advise the Food Directorate of any changes that may affect the
validity of the no objection status.
 However, The Food Directorate reserves the right to rescind the no objection status of any given material
should information come to light showing that its use may potentially pose a health risk to consumers.
4. Guidance Documents/Guidelines
 Food packaging material suppliers may consult the guidance document under "publication" for details
concerning the Information Requirements for Food Packaging Submissions.
 Recycled plastics used for packaging foods are subject to the same regulations as virgin plastics in terms of
their chemical safety.
VIVEK SINGH BASC IV

 Food packaging suppliers whose products contain recycled plastics should also consult the document
entitled Guidelines for Determining the Acceptability and Use of Recycled Plastics in Food Packaging
Applications under 'publication".

Q. explains with neat different working of different types of size press and factors influencing size press pick up?

Surface sizing is done by 3 different processes

1. Size press
2. Size tubs
3. Calendar sizing

1. Size press:-
 Types of size press are
1) Vertical size press
2) Horizontal size press
3) Inclined size press

Vertical size press Horizontal size press Inclined size press

1) Vertical size press

 Size press consists of pair of top and bottom rolls
 Paper from dryers at 4 – 12% moisture is led to top roll at an angle of 60 o and leaves the roll at similar angle
for drying
 Surface sizing solution with or without pigments is fed to felt side and forms a pond at ingoing nip and
bottom roll is surrounded by a trough
 Top roll is a dead hard rubber covered roll, a stonite roll or a brass roll
 Bottom roll is softer rubber covered roll and its hardness determines the amount of pickup of size
 A spring roll is located ahead of press to keep tension constant and to control angle(usually about 25 o) at
which paper enters the nip and also determines the area of puddle
 Lowering the angle increases angle of puddle and thereby pick up of the size
2) Horizontal size press
 In the Horizontal size press the two rolls are side by side and size is sprayed into the nip on both sides of the
sheet while the sheet travels downward through sizing solution
 Size is introduced in the nip at the center of the sheet and flows from center towards both ends
 As the sheet passes downwards
– the sheet need not support a pond of sizing solution
– draw need not be tight as in vertical press
 Pond is usually kept just large enough to provide little size running off the ends of the rolls
 Vertical configuration provides the easiest sheet run but the pond depth of solution in each nip is unequal
 The horizontal size press solves the problem of unequal absorption by providing identical pond forms on
either side of the sheet
3) Inclined size press
 The inclined size press is a compromise, developed to avoid
 the awkward vertical sheet run of the horizontal size press
VIVEK SINGH BASC IV

2. Size tube
 The tube sizing is usually located separately after the paper machine and dried on special dryer .they may be
placed between pre and post dryer.
 The paper is passed over paper roll and is immersed into a liquid filled in tube.
 The paper after sufficient immersion is passed between two press roll.
 The distance(gap) between the two roll regulates the amount of size on paper
 The paper send for drying
 Top roll is provided with doctor blade for cleaning and to prevent the sheet from binding around the roll.
3. Calendaring sizing
 Heavier paper and board are commonly surface sized at calendar stack to obtain smooth and pick resistance
surface for printing and also to get improved calendaring action.
 The sizing solution is applied by means of size box, placed against alternative side of the roll of stack.
 The solution is carried on the roll surface into the nip where it is applied to the paper

 Factors influencing size press pick up

1. Sheet characteristics
a. Paper substrate(basis weight, density, smoothness, capillary structure, void size etc)
b. Level of internal sizing
c. Moisture content

2. Sizing solution
a. Solids content
b. Temperature
c. Viscosity (fluidity)
d. Composition(type of starch, use of additives)

3. Design and operational

a. Machine speed
b. Pond depth
c. Nip pressure
d. Nip width(affected by roll hardness and diameter)

Q. Explains letterpress and flexographic printing process with paper requirement and application?
Ans .

LETTERPRESS
Paper Requirement:-
- Smoothness and levelness
VIVEK SINGH BASC IV

- Resilience
- Compressibility
- Bulk and receptivity
- Ink holdout
- Require uniform paper (grammage, moisture 5, caliper, water absorption and less two sidedness ) plus
adequate optical property and good runnability in printing process
Print
PROCESS:-
Paper

 Letter press is the most common type of printing process Impression

 The letterpress Cylinder

- Printed from raised surface of metal plates

- Medium long runs
- High quality printing
- Oil based inks, expensive plates
 In recent year ,intermediate plate or cylinder technology have
been enhanced Plate
 Letterpress is only method by which printing is done directly Cylinder

 In this process ink is transferred from the ink roller to printing

plate and subsequently to the paper by raised surface with Ink
moderate pressure
 Paper for letter press printing experience the greatest pressure
 at printing press nip. Ink Rollers
 After printing it is dried

Application
– News paper
– Magazines
– Paperback books

FLEXOGRAPHIC
Paper requirement
- Water resistant
- Ink holdout
- Oven stability
- Require uniform paper (grammage, moisture 5, caliper, water absorption and less two sidedness ) plus
adequate optical property and good runnability in printing process

Process
 Flexography is a form of relief printing which uses rubber or resilient plastic plate with simple soluble type ink
 This process resemble a letter process including a relief operation however instead of ink roller finely engrave
Anillox roll provides uniform ink transfer onto the flexible printing plate
 The water based ink are recent development and are encouraging the use of IR drying
 Flexography advantages
- Ability to print on many surface types
- Inexpensive, can use water based inks
- Good for long runs
- good ink absorbency
- even full tones without pattern
- high dot definition (no “shadow”)
- fast ink drying
- good ink adhesion
VIVEK SINGH BASC IV

Application Anilox roll

– Boxboard
– Films & foils
– Corrugated cartons
– Low cast magazine
– News paper
– Paper bags

Q. A MICR roll is placed at back stand of rewinder .it is to be converted into reel size of i. 23cms x 2 iii. 30.5cms x4
iii. 46cm x 1 iv. 91.5 cm x1 these reels weigh approximately 113kg, 149kg, 226kg and 449kg respectively when
wound to standard size .the parent roll at 305.5cm deckle weigh 4.5 MT and basis weight of paper is 95gsm
calculate
i. Length of paper in parent roll
ii. Number of standard reel in each size

Ans :
23|2 + 30.5|4 + 46|1 + 91.5 |1

= (46 + 122+ 46+ 91.5) cm

= 305.5cm

The deckle of parent roll is 305.5cm

a) 23cm x 2 = 1 reel =113kg

For 2 reel = 226kg

b) 30.5cms x 4 = 1 reel = 149kg

For 4 reel = 226kg

c) 46cms x 1 =1 reel = 226kg

1 reel =226kg

d) 91.5cms x 1 =1 reel = 449kg

1 reel =449kg

Total wt of reel at first set =226+596+226+449+=1497kg

Total wt of reel at second set = 1497kg
Total weight of reel at third set =1497kg
Total weight of parent roll=4491kg

Number of standard reel in each size

a) 23|2 = 2 x3 = 6reel
b) 30.5|4 = 4 x3 = 12reel
c) 46.0|1 = 1 x3 = 3reel
d) 91.5|1 = 1 x3 = 3reel
VIVEK SINGH BASC IV

Length of paper in parent roll

= W X105
CXg

= 4.5 x1000 x 105

305.5 x 95

= 15505.21 m

Q. Explain various coating additives with their function and factor affecting
Ans
1. Pigments
Example - Clay, PCC, TiO2, Plastic Pigments (Polystyrene)
Function - Builds a fine porous structure and provides a light scattering surface.
Properties affected: - colour brightness opacity, paper and ink gloss, smoothness and holdout.

2. Dispersants
Example – Polyphosphates, Lignosulfonates, Silicates
Function
- Dispersent are low molecular weight material that are absorbed to pigment surface proving enhanced
stability by keeping the particle associating to each other
- It is used to disperse pigment to achieve minimum viscosity at high speed disperse rate

3. Cross linkers
Example –urea formaldehyde, glyoxyl
Function –
- The water soluble binder tent to lose their binding power when it come in contact with water and get
dissolved. The water sensitivity of binder can be decrease by cross linking the soluble binder together with
Insolubilizer by building hydroxyl and carbonyl group around bonder.

4. Binders
Example:-
- Natural (starch and protein)
-Synthetic (styrene butadiene, polyvinyl acetate, polyvinyl alcohol, styrene-acrylic, vinyl-acrylic)
Function –
- Binds pigment particles together.
- Binds Coating to paper.
- Reinforces the base sheet.
- Approximately 18% of the coating
- The binder can be classified as main binder ,co-binder and sole binder
- Main binder - binding function
- Co-binder – affect the Rheology and water retention properties of coating colour
- Sole binder –perform all function

5. Lubricants (calcium stearate most common)

Example – Stearate, Wax emulsions
Function - Improves the flexibility of coating films.

6. Anti-Foam Agents
Example:-
Function
- Controls foam problems.
VIVEK SINGH BASC IV

- Eliminates air bubbles.

7. Rheology Modifier
Example: - (CMC, HEC, polyacrylates, sodium alginate)
Function – Controls coating viscosity and water retention properties.

[Link] Brightener
Example:-OBA
Function- it will provide attractive colour and brightness

Q. Describe the printability and runnability with respect to printing paper evaluation?
Ans:
RUNABILITY Printability
Affected by: Affected by:
•Printing machine •Printing method
•Ink •Printing machine
•Paper •Ink (Ink gloss, Ink set-off)
•Environment (RH & temperature) •Paper
•Operator •Environment (RH and temperature)
RUNABILITY –UCWF Paper •Operator
Affected by: PRINT QUALITY –UCWF Paper
•Picking resistance, dusting Affect on print quality:
•Internal bonding strength •Whiteness
•Stiffness •Opacity
•Dimensional stability •Smoothness
•Tensile strength (for web) •Formation
•Tear strength (for web) •Picking resistance, dusting
Cobb/Dimensional stability

 Printing properties may be divided into printability and runnability

 The printability of paper results from complex interaction between printing ink ,printing process and
paper
 Practice –oriented printability test must be performed to evaluate these properties.
 Instrument for offset printing ,gravure printing and flexographic printing can be used with standard
ink under laboratory condition to test the
a) Strength property - Pick strength (dry & wet) ,Ink Refusal, Offset test, Wet rub, Blister resistance
b) Appearance Sheet –gloss, Smoothness &Brightness
c) Print Quality-, Mottle (1or2 colour) ,Ink wipe test(K&N,croda, porometrique) ,Helio test

Printability
1. off set
 high print gloss
 even halftones
 detailed tonal gradation
 low ink consumption (high density)
 high dimensional stability of the paper
 sharp dots / controlled dot gain
 fast ink drying for immediate processing
 controlled water/ink interference
 low fiber roughening (web-dryer)
 no “blistering” (web-dryer)
2. Rotogravure
VIVEK SINGH BASC IV

 detailed tonal gradation

 few missing dots
 sharp dot
 high print gloss
 low ink consumption
 good machine performance (splices)
 consistent moisture (electro assist effect)
3. Flexography
 good ink absorbency
 even full tones without pattern
 high dot definition (no “shadow”)
 fast ink drying
 good ink adhesion
4. Ink jet
 good ink absorbency
 even full tones without pattern
 high dot definition
 fast ink drying
 good tonal stability (no colour shifting)
 no “bleeding”
 no “feathering
Q Describe offset and rotogravure printing process with paper requirement and application?
Ans
1. OFFSET printing process
Paper requirement
• Receptivity (ink & water)
• Water Resistance
• Smoothness (Sheffield)
• Stiffness
• Coating pick strength
• Ink holdout
• Oven stability (blistering)
colour

fountain

Impression cylinder
Process
 This process is Based on the principle that oil and water don’t mix
 unlike letter press and flexography ,offset is not relief process
 Instead the printing cylinder plates has separate area which is either receptive to water or oil on ink vehicle
 A soft rubber blanket offset that transfer both to the paper
 Offset printing can print on both side at the same time using as much colour
 Drying may be cold ser or heat set
VIVEK SINGH BASC IV

 Along with basic requirement as far other printing process lithographic printing process paper require good
smoothness and surface strength to prevent debris accumulation on the blanket and good dimension
stability to resist the influence of fountain water
Application
 News paper
 Magazine
 Book
 Catalogs
 Greeting cards ,business form
 Cheque paper
 Labels etc

2. Rotogravure printing Print

Paper requirement Paper

- Smooth & level (PPS-10, no curl) Impression

Cylinder
- Compressible
- Free of surface debris
Gravure
- Soft coating Cylinder
Gravure
Cylinder
- Ink holdout
- Uniform GSM ,moisture ,caliper ,formation Doctor
Blade
- Water absorption and two sidedness plus optical property
Process Ink Pan

 Gravure is major exponent of intaglio process.

 It uses cylinder and has an advantage that it can change the printing length by changing the cylinder.
 Because the cylinder is expensive to produce it has been used for long print run.
 In gravure printing, the image is engraved onto cylinder and this is partially immersed into pan
containing the ink
 As the cylinder rotates it draws excess onto the surface and into the cell
 The doctor blade scrape the cylinder to remove excess before it make contact to paper surface
 Next the substrate gets sandwiched between impression roll and gravure cylinder and due to this ink gets
transferred from gravure cylinder to substrate.
 The purpose of impression cylinder is to apply force ,ensuring that entire substrate is brought in contact
with gravure roll
 Then the inked substrate goes through dryer for drying

Application:-
 Currency
 Bond certificate
 Stamps
 Greeting card
 Magazines
 Business form
Q. A coating colour preparation uses 500g super coat clay/batch with following component. Calculate each of them
required on dry and as such basis on weight .calculate the weight of fluid required for dispersion of clay and CaCO3 at
68% w/w.
Component Quantity (part) Moisture % /solids %
Super coat clay 75 1% moisture
Calcium carbonate 25 2% moisture
Dispersent 1 0.45 on clay 40% solid
Dispersent 2 0.20 on CaCO3 40% solid
Binder 17 50% solid
Co binder 0.5 4% solid
Lubricant 0.65 45% solid
Insolubilizer 0.5 45% solid
VIVEK SINGH BASC IV

Ans

Component Quantity (part) Moisture % /solids %

Super coat clay 75 1% moisture
Calcium carbonate 25 2% moisture
Dispersent 1 0.45 on clay 40% solid
Dispersent 2 0.20 on CaCO3 40% solid
Binder 17 50% solid
Co binder 0.5 4% solid
Lubricant 0.65 45% solid
Insolubilizer 0.5 45% solid
Total 119.3

1. Total dry solids = (dry clay /batch x total parts) /(individual part of clay )
= (500 x119.3)/ (75)
=795.33gm

a) Clay on dry basis =(clay part individual x total dry solids) /(total part )
= (75 x 795.33)/ 119.3
=499.9gm
Clay as such basis = (OD x100)/ (100-M %)
= (499.9 X100)/ (100-1)
=504.9 gm
b) CaCO3 on dry basis = ( part individual x total dry solids) / (total part)
= (25x 795.33)/ 119.3
=166.67gm
As such basis = (OD x100)/ (100-M %)
= (166.67 X100)/ (100-2)
=170gm
c) Dispersent-1 on Clay = (part individual x total dry solids) /(total part )
= (0.45 x 505.9)/ 119.3
=1.91gm
Dispersent -1 as such basis = (OD x100)/ (100-M %)
= (1.91 X100)/ (100-60)
=4.775 gm

d) Dispersent-2 on CaCO3 = (part individual x total dry solids) /(total part )

= (0.20 x 170)/ 119.3
=0.284gm
Dispersent -2 as such basis = (OD x100)/ (100-M %)
= (0.284 X100)/ (100-60)
=0.71 gm

e) Binder on dry basis =( part individual x total dry solids) /(total part )
= (17 x 795.33)/ 119.3
=113.332gm
As such basis = (OD x100)/ (100-M %)
= (113.33 X100)/ (100-50)
=226.66 gm
f) Co-binder on dry basis = (part individual x total dry solids) / (total part)
= (0.5 x 795.33)/ 119.3
=3.33gm
As such basis = (OD x100)/ (100-M %)
 VIVEK SINGH BASC IV

= (3.33 X100)/ (100-96)

=8.32gm
g) Lubricant on dry basis = (part individual x total dry solids) / (total part )
= (0.65 x 795.33)/ 119.3
=4.33gm
As such basis = (OD x100)/ (100-M %)
= (499.9 X100)/ (100-55)
=9.63 gm
h) Insolubilizer dry basis =( part individual x total dry solids) /(total part )
= (0.5 x 795.33)/ 119.3
=3.33gm
As such basis = (OD x100)/ (100-M %)
= (499.9 X100)/ (100-55)
=7.04 gm

Component Total dry solid Total solid as such

Super coat clay 499.9gm 504.9 gm
Calcium carbonate 166.67gm 170gm
Dispersent 1 1.91gm 4.775 gm
Dispersent 2 0.284gm 0.71 gm
Binder 113.332gm 226.66 gm
Co binder 3.33gm 8.32gm
Lubricant 4.33gm 9.63 gm
Insolubilizer 3.33gm 7.04 gm
Total 793.08 936.81

 Weight of dry solids = 499.9 + 169.67=669.7gm

Percentage solid by weight = (wt of dry pigment x 100)/ (wt of dry pigment + water)
68% = (669.7 x100)/ (669.7 + x)
X = 981.91 -669.6= 312.2ml

Q. Explains in detail corrugated board testing?

A. Tests on corrugating medium

1. Ring crush or stiffness in edgewise direction which co relates with compression test on the finished box
- Cross direction ring stiffness relates to top to bottom box compression and machine direction ring
stiffness relating to end to end box compression
Procedure –
 VIVEK SINGH BASC IV

 Force required to buckle a strip of paper or board circle on edge

 Sample is size of 1/2ich wide and 6 inch long
 The sample is inserted in annular gravure formed between the disc and round flat aluminum base
 This same holder is placed between the two platen (constant speed ) crusher tester
 The upper platen is connected to motor driven through spindle by longitudinal weight
 The lower platen is connected to the deflection beam which in turn is connected to dial recorder
 The force is applied by upper platen on to the sample is transfer to the lower platen and amount of
deflection is measured by the dial recorder And it is calculated as kgForce unit

2. Concora test – The corrugating medium is tested by fabricating in to flutes which predicts the flat crush to be
obtained on the combined board. Low results indicate the board will be soft and too high results may cause
fractured flutes and result in operating difficulties.
Procedure
 Series of tests to determine the rigidity and crush resistance of corrugated material.
 The first test measures the flat crushing resistance of a laboratory-fluted corrugated material.
 The second test determines the edgewise strength, parallel to the flutes, of a short column of single-,
double-, or triple-wall corrugated board.
 The third test evaluates the ability of corrugated material to contribute to the compression strength of a
corrugated box by measuring the edgewise compression strength of a laboratory-fluted strip of corrugated
material in a direction parallel to the fluted tips.

3. Modulus of elasticity of the paper board components is significant in determining the rigidity and resistance to
compression.

B. Tests on corrugated Board

1. Bursting strength – Specimen is placed in bursting strength tester and hydrostatic pressure is applied till it
rupture .Record the maximum pressure recorded by pressure gauge.

2. Flat crush test – It is measure of the resistance of the flutes in corrugated board to a crushing force applied to
the surface of the board under prescribed conditions.
 Flat crush is a measure of the flute rigidity of corrugated board.
 A high flat crush value indicates a combination of good flute formation
 Low flat crush indicate low strength medium, leaning flutes and crushed flutes.

3. Puncture test – Done on dynamic tester measures the cushioning quality of corrugated board
4. Pin test – measures adhesion between the liners and corrugations
5. Creasability – resistance to creasing and bending
6. Water resistance – soaking board in water for 24 hours
7. Visual examination – high low corrugations, leaning flutes, poor flute contour, adhesive spots, crushed flutes,
poor gluing at edges, liner damage, blisters, brittle bond, pronounced finger lines

C. Tests on corrugated Box

1. puncture test and the compression test
 Top to bottom compression of the corrugated box is determined by measuring
- compression resistance of the flutes in the glued board
- compression resistance(cross direction) of the paper liner
 This is because
- flutes are always glued perpendicular to the machine direction of the liner
box is fabricated with the MD around the sides of the box
- The end to end compression of the corrugated box is determined by measuring
the MD compression resistance of the liner alone
2. Drum test- where loaded box is allowed to fall inside a revolving drum until it fails. Test is done to see its
performance in rough handling
3. Drop test- where loaded box is dropped from a height of 42 inch and test is repeated until a predetermined
point of failure has been reached
VIVEK SINGH BASC IV

Q writes a note on problem faced in printing?

VIVEK SINGH BASC IV

Haze

 This is printing defect in gravure printing process

 Characterized by printing in non-image areas, caused by incomplete ink removal from the surface of the
gravure cylinder by the doctor blade.
 The term haze also refers to any milky discoloration of a transparent film or liquid solution, such as a printing
ink, in any printing process.
Tinting
 A general scum that forms on non-image areas of the printing plate and is transferred to the paper
 In particular, tinting occurs when particles of ink pigment bleed into the fountain solution, and are
transferred to the non-image areas of the plate, printing as a colored tint.

[Link] a note on waterless lithography printing and inkjet printing?

Ans
 In lithography water is used in non image areas to prevent application of oil based inks
 Water causes problems of
- ink water balance
VIVEK SINGH BASC IV

- control of colour
- Paper waste
- Paper distortion
 If water can be replaced with something that is more controllable lithography will improve
 The driographic process eliminates water in lithography where a silicone coating is used to cover the non
image areas of the plate to prevent ink pick up in these areas
 The image area is created photo mechanically by removing the silicone coating
 This leaves ink receptive base substrate open to ink system
As water is eliminated, inks can be made with brighter, more dense and durable pigments and paper does not have
to be made water resistant
 Plano graphic plate can be run on existing lithographic press by removing wetting system and changing to
special hi tack driographic ink

 The problems associated with driography are

- Very high tack inks to be used
- May cause paper picking
- Set off marking
- Slow drying
- Poor ink lay
- Back ground tinting
- Paper lint
- Paper coating sticking to the dry blanket and paper handling problems
Ink jet Printing

 Flexibility is the most important requirement in printing and this can be met with the use of a computer
controlled printer
 Such a system uses an array of jet nozzles to release charged or uncharged ink droplets towards a charged
medium covered with paper
 The charged droplets are electrostatically deflected in to a catcher for non image areas while the uncharged
droplets continue in flight forming dots on the printing surface and constructing an image
3 basic inkjet systems are

a) High frequency pressurized electro statically deflected

b) Low frequency pressurized electro statically deflected
c) Low to medium frequency non pressurized ink on demand
 The number of dots can be increased by either increasing the number of droplet/s/jet or by increasing the
number of jets/array
 Dot characteristics are influenced by the nature of substrate and ink
 Ink jet systems cover range from slowest dot matrix systems using impulse jets to high speed multiple jet
arrays at 125000 characters
 They range from the minimum quality just legible characters used in label coding to typewriter quality
characters
Advantages of Ink jet system
 This process requires no plates, wash ups or make ready
 Images can be changed during printing if desired
 Sequential printing of books, magazines or news papers is possible
 Ink jet printers can be put in line with conventional printing
 presses for marking each piece differently as it passes the press
 good ink absorbency
 even full tones without pattern
 high dot definition
 fast ink drying
 good tonal stability (no colour shifting)
 no “bleeding”
 no “feathering”
VIVEK SINGH BASC IV

Q. Explain construction and working of Massey coater and roll coater giving their merit and demerit

Metering
Distributing roll roll
Applicator roll
Coating
reservoir
P&J
50-60

Oscillating
roll Calendar

Applicator roll

Construction &Working:

 It consists of a no. of rubber covered rolls including a pair of two metering rolls, distributing rolls and large
applicator roll.
 The applicator roll diameter 81.3-121.9 cm with P & J 50-60, distributing (transfer) rolls having 45.7-50.8cm
with P &J 160-180, and metering roll is having diameter 45.7-50.8cm with P & J 90-100.
 The distributing rolls meters the coating solution distributes and controls the coat weight.
 The transfer rolls pick up the film of coating from the metering rolls and transfers to the applicator roll.
 In this process paper coated on both side wile on machine. It is typically of printing roll coater which work
with coating solution 50-60% solid content.
 The coating solution is metered by metering roll and then this coating solution is transferred to distributing
roll which intern transfer the coaling solution to applicator roll and this roll transfer the solution to base
paper.
 Coating mixture usually contain pigment(clay) and binder(modified starch) and other addivies
Roll coaters

1. Metering: Applying proper amounts of treatment to application roll

2. Applying:
- Applying treatment to substrate
- Application rolls may be engraved or embossed so that only part of the substrate is coated
- A second set of metering and application rolls may be located below to coat the other side
3. Burnishing
- Leveling the treatment on the substrate
VIVEK SINGH BASC IV

- Burnishing rolls usually rotate in a direction opposite to the substrate direction

 Merits

1. Advantages of giving an even coat weight, even when the surface of the base sheet is somewhat rough.
2. It is used at speeds of 600 m/min (2000ft/min),
3. High solid content coatings with high viscosity.
4. These coaters have low maintenance.
 Demerits

1. The disadvantages are the large space requirements,

2. film splitting, high installation costs, and
3. The requirements of numerous adjustments.
4. Coating weights are limited to about 10 g/m2, although two layers are used sometimes.

Q. Explain packaging material life?

 This process describes how packaging materials are created, manufactured, used and disposed of, recycled
or re-used. Each stage has potential economic, social and environmental costs and benefits.

 Stage 1: Designing
The designer creates a plan for packaging that meets the functional requirements like cost and
durability, as well as sustainable design principles or criteria.

 Stage 2: Extracting
The raw materials are harvested from renewable sources like forests, or mined from the earth, in the case of
metals or oil-based plastics.

 Stage 3: Manufacturing
Machinery, energy and water are typically involved in the processes that turn raw materials like wood, aluminum
and oil into packaging materials like paper, tin and plastic; and then turn these materials into boxes, bottles,
bags and other forms of packaging.

 Stage 4: Filling
Both machines and human labour are involved in placing products in primary packaging, placing primary
packages in secondary packaging and stacking and securing secondary packaging on transit pallets

 Stage 5: Distributing
When the products are packaged, they are moved into warehouses for storage and/or transported to the
customer for use or retail. Some products require controlled storage environments, like refrigeration
VIVEK SINGH BASC IV

 Stage 6: Retailing
Most packaged products are sold through retailers. Products may have special storage and display
requirements, like refrigeration, and may have a limited shelf life.

 Stage 7: Using
Once purchased by a consumer, packaging may provide short- or long-term storage for the product. It may
feature directions for product use and package recycling.

 Stage 8: Disposing
When the packaging is no longer needed, it can be re-used, recycled, sent to landfill or incinerated for energy
recovery.

Q. Explain different type of printing ink with method of drying and recycling possibility?
Ans
 Types of printing inks
The various classifications of inks are based primarily on their drying methods which, in turn, are based
on the vehicle each ink uses

Q. writes a note on evaluation of printing paper?

Ans
Evaluation of printing paper
Major customer for coated printing paper is Graphic Arts printer and knowledge of specific requirements and
how to measure them is extremely important
1. Graphic Art Printing
a) Smoothness - printing quality of paper is measured by smoothness, the rate of passage of air
b) Thickness is also an important test because most printing processes depend on pressure to help transfer of
the ink
VIVEK SINGH BASC IV

c) Oil absorption – shows how ink will take on a given paper, quick absorption of oil indicates good ink
receptivity
d) Wax pick test –
- Testing for pick is done by this
- Picking on the press may be caused by un favorable press conditions also
- Too much pressure may break the coating causing picking
e) Softness –
- Is a measure of compressibility of the paper
- Often a soft paper which is rough will print as well as a hard paper that is smooth
f) Grit in paper –
- Is measured by a smooth glass plate or a silver coin
- Cannot be measured numerically
g) Surface pH –
- A litho coated paper should have a surface pH as near neutral as possible
- An alkaline coating neutralizes the fountain solution and causes problems
- Other chemicals in papers may effect the colour of printing by combining with the ink and changing pigment
colors
- Excess alum in paper may also cause problems
h) Blott ability and coverage –
- Illustrate ink receptivity i.e the manner in which the paper surface blots the printing ink from the plate
- Can be tested by using a proof press or by trial run on the printing press using a solid plate and measuring
drying and penetrating time
i) Two sidedness –
- Often requires charges in the colour of the ink to be used when the second side is printed
- 3 to 4 colour printing is also affected by two sidedness
j) Opacity – is a measure of the show through of printing
k) Transparency – caused by oil penetration will often make a paper with a good opacity appear to have low
opacity
2. Letter press & gravure printing
 As Letter press inks are generally tacky paper needs good surface strength. Many important properties that
can be studied in lab are Smoothness, Oil, vehicle or solvent penetration by absorption. Presence of abrasive
particles, Sheet density, Softness, Bulk. By evaluating all these property probable behavior of paper on press
can be determined.

3. Aniling printing
Aniline inks are applied by letter press or gravure method .Sheet must have minimum basic strength like
tensile strength ,tearing strength etc requirement but specifications are not as rigid as gravure or letterpress
Range of paper used varies from a practically un sized tissue to a very highly sized and coated friction glazed
box paper
 If the sheet is to be varnished good sizing, ink hold up gloss and smoothness required
As wide range of products is used specific tests cannot be given.
4. Surface printing
 Surface printing is specific to the specialty converting Industry
 Base papers range from fine tissues for Christmas wraps to wall papers and fancy box papers
 These papers require good physical strength, certain minimum surface strength as fairly heavy inks are used
 Wide variety of papers and broad field of application make it difficult to have specific evaluation
Q. Explain laser and thermal printing in detail with requirement paper?
Thermal Printing
 Done by converting electrical signals directly to heat to produce characters or symbols on thermal sensitive
paper with heated dot matrices
Advantages are
- Reliable hardware
- Silent
- Low power due to high efficiency of direct electrical to Thermal energy conversion
- Clean as no ink, powders or fixing actions are required
VIVEK SINGH BASC IV

Some of the problems faced are

- Abrasions due to print heads rubbing against the paper
- Inter connections
- Alignment leading to poor thermal transfer and burnout
- Limited speed of character printing
- Lack of sufficient cooling time results in ghost images

LASER PRINTING

 LASER stands for Light Amplification by Stimulated Emission of Radiation

 Laser is a powerful, highly directional, monochromatic and coherent beam of light which can form
extremely accurate images
 Offset, gravure, letterpress or screen printing plates could be made with laser.
 Heat sensitive papers or electro photographic papers or plates can also be imaged.
Process:

 Steps of process are as follow

1. Cleaning :-this is first steps where the photosensitive drum is cleaned by the blade scraper to
remove the excess tonner that remained from previous cycle .this done to get proper image on
the drum
2. Conditioning:-to negatively charge the photosensitive drum. Where sending an ionic charge
through a wire in laser printer due to this drum gets negatively charged.
3. Writing image:-here the image or text in form of laser is directed onto mirror and mirror reflects
this beam on to photosensitive drum to imparting a charged dot pattern.
4. Develop: here the tonner which is in powder form and is negatively charge will attach to
photosensitive drum at that point where the laser touched it.
5. Transfer: - here the image formed on the photo sensitive will be transferred to the base paper.
6. Fuse:- this is process of fussing tonner onto paper with help of heat as shown in above diagram
 Advantages:-
- Very high quality
- Fast printing speed
- Easy operation as free of moving mechanical parts of a press
- Economically justified process

 Limitations
- Laser is not sometimes cheap to use
- High loss of energy when electricity is converted to laser light to do work
- Weak or powerful, it is hazardous light – can cause eye damage if not properly shielded

Q. Explains in detail paper type used in packaging?

5 marks
VIVEK SINGH BASC IV

Q.1 what is Difference between on machine and off machine coating?

On machine coating Off machine coating

1. The coating of paper is performed while it is 1. The coating of the surface of a paper performed
still on the papermaking machine. after it has come off the papermaking machine

2. The advantages of on-machine coating involve 2. The advantages of off-machine coating are the
elimination of the necessity of winding, packing, speed and efficiency of utilizing special equipment
and shipping paper rolls of base stock to a designed just for coating
separate coating plant

3. Disadvantages include the necessity of having 3. The base stock produced by more than one
to shut down the entire papermaking process if papermaking machine can be coated using one
difficulties in the coating section arise machine.

4. the necessity of shutting down the coating of 4. Disadvantages include the necessity of winding,
paper if difficulties in the other portions of the packing, and shipping paper rolls
papermaking system arise

5. on-machine coating processes are not suitable 5. off-machine coating processes are suitable for
for all paper grades. all paper grades.

Q.2 Explain the working of size press with neat diagram.

Ans.

 Types of size press are

1) Vertical size press
2) Horizontal size press
3) Inclined size press

Vertical size press Horizontal size press

Inclined size press

1) Vertical size press

 Size press consists of pair of top and bottom rolls
 Paper from dryers at 4 – 12% moisture is led to top roll at an angle of 60 o and leaves the roll at similar angle
for drying
 Surface sizing solution with or without pigments is fed to felt side and forms a pond at in going nip and
bottom roll is surrounded by a trough
 Top roll is a dead hard rubber covered roll, a stonite roll or a brass roll
 Bottom roll is softer rubber covered roll and its hardness determines the amount of pickup of size
 A spring roll is located ahead of press to keep tension constant and to control angle(usually about 25 o) at
which paper enters the nip and also determines the area of puddle
 Lowering the angle increases angle of puddle and thereby pick up of the size
VIVEK SINGH BASC IV

2) Horizontal size press

 In the Horizontal size press the two rolls are side by side and size is sprayed into the nip on both sides of the
sheet while the sheet travels downward through sizing solution
 Size is introduced in the nip at the center of the sheet and flows from center towards both ends
 As the sheet passes downwards the sheet need not support a pond of sizing solution and draw need not be
tight as in vertical press
 Pond is usually kept just large enough to provide little size running off the ends of the rolls
 Vertical configuration provides the easiest sheet run but the pond depth of solution in each nip is unequal
 The horizontal size press solves the problem of unequal absorption by providing identical pond forms on
either side of the sheet
3) Inclined size press
 The inclined size press is a compromise, developed to avoid
 the awkward vertical sheet run of the horizontal size press

Q. what is lamination? Explain the process with all the accessories required?

 Definition – Process of combining of like/unlike substrates with adhesive to improve appearance,

strength and also to improve utility (usefulness)
 Process is performed in mill & in converting plant
Accessories:
BASE PAPER
 Any type – Unbleached and bleached Kraft, tissue etc
 Selection – desired properties
- Aluminum foil – for packaging and industrial uses
- Lead and tin – lower properties
 High strength, increased impermeability, good stability – cellophane, poly ethylene, polyester
 Less commonly used – polystyrene, poly urethane, polypropylene, nylon
 Cloth and fabrics –
- Ordinary uses - nylon, cotton
- High strength, durability, tough packing – fiber glass, burlap, jute

ADHESIVES
Class 1 – dry laminating adhesive
Ex - Starch, dextrins, vegetable and synthetic gum proteins, cellulose derivatives, silicates
Class 2 – Applied in molten condition
Ex - Thermoplastic waxes, synthetic resins
Class 3 – Chemical activity – polymerization, heat, pressure, radiation, catalyst, exposure to moisture
LESS USED IN LAMINATION
Ex - Epoxy, Dimethacrylate, cyanoacrylate, polyamide etc
Process of lamination
1) Applying the adhesive
2) Combining the plies
3) Setting the adhesive
Applying the adhesive

 Application of Uniformly distribution and accurately controlled film of adhesive important

 Success of entire process depends on this step
 Too much or too little or uneven application leads to poor, spotty or no bonds
 Applied widely by roll coater, calendaring or sizing
 Extrusion coating is accurate but complex way of application and eliminates outer environmental
influences like drying, cooling, contamination etc.
 Spray application used in packaging operation
 Dip, flood or tub sizing may be used
 Minimum quantity of adhesive that will wet and fill the voids must be used
Combining the plies
VIVEK SINGH BASC IV

 All laminating processes involve period of open time before joining substrates with applied adhesive film and
opposing substrate surface.
 May be minutes, hours or days but fast converting operations limit to seconds
 Adhesive begins to set during open time
 Long distance between glue application and pressing (long time) provides setting & cooling prior to pressing
 But long time may result in more penetration or spotty wetting of opposite substrate
 Pressure is required to join substrates and manner of application, amount of pressure and duration of force
affect intimacy of contact
 High pressure spreads adhesive in to thin film or force it in to substrate
 Too less pressure results in poor bonding
 Rolls are commonly used with controlled nip pressure and angle of contact
Setting the adhesive

 Final step in forming laminate includes drying, cooling and curing of adhesive
 It is necessary to dry, cool or heat the laminate to speed up Setting
Drying –

 water or organic solvent from laminates is done by passing web through heated chamber over heated rolls
 Cheap low solid adhesive needs more energy than high solid adhesive with little or no drying
Cooling –

 Laminates combined with hot melt, heat sealed or wax

 Laminated need cooling for rapid setting
 Done by passing web over cooled or chilled rolls
 Though the cooling costs are less the initial melting cost of these adhesives makes them expensive
Curing –
- Setting of polymerized adhesive needs heating laminate as chemical reaction at high temperature is rapid
- Along with function of holding the plies other functions of adhesive are
 Insensitivity to water
 Control of curl
 Complete re pulp ability
 Greater opacity
 Increased stiffness
Q .how are corrugated paper tested

What are fiber drum? How are they produced? Where are they used?
Ans.
Fiber drum: - fiber drum is cylindrical container with sidewall made of paper or paperboard having ends and
component made of similar or other material such as metal, plastic, plywood or composite material.
Manufacturing process:-
VIVEK SINGH BASC IV

 Fiber drum varies in size with diameter from 180mm to 600mm and height from 75mm to 1800mm
 They are made from fibrous material and to get desired strength characteristics ,are invariably cylinder in
shape with parallel side walls
 Making of side wall
There are two methods than can be used for side wall making
a) Spiral winding: in this several plies of paper wound around a stationary mandrel, each ply being
wound in helix or spiral, overlapping, superimposed upon to the ply below.
b) Convolute winding: where several individual rectangular sheet or web of paper are wound around a
rotatable mandrel ,resulting in several sheet or several turn of web being directly superimposed
upon and bonded to sheet or ply below
 It is essential that all plies are firmly glued together overall to form solid side wall.
 The adhesive used will depend upon use for which the drum is being made.
 The normal adhesive used is sodium silicate ,but starches ,dextrins or special waterproof adhesive are
employed
 Drum ends and lid can be made from fiber board or steel
 Regular drop tests confirm that the drums comply with UN regulations for transportation of hazardous
goods.
Application:
 Fiber drums fulfill a large number of packaging requirements, in particular for the chemical, pharmaceutical,
glue, paint and food industry.
 Specialty drums, including cheese drums, a feed pack, tapered drum and a Harvest pack for transport of
tomato paste, purees and particular food products.
 Drums provide optimum protection for a large variety of hazardous and non-hazardous products.

Q. write note on extensible sack Kraft paper?

Ans
 Extensible sack Kraft paper is high porosity combining high tensile energy absorption (TEA), high stiffness,
excellent runnability and very good printability.
 Advantage is a new range of sack Kraft paper products, offering solutions to a multitude of testing
requirements, applications and end uses.
 Products are designed to overcome any challenge, from varied filling materials to extreme climatic
conditions.
 Portfolio includes brown, white and PE coated paper grades for valve and open mouth sacks.
 It has been developed for the filling of a wide variety of powdered goods, including cement, building
materials, chemicals, food and animal feed.
 Recommend to use without perforation for quick filling of one ply valve sacks.
 This reduces the dust level during filling and handling of the sacks significantly and has shown increased slip
resistance.
 Benefits
 Strength, Stiffness, Porosity, Printability, Runnability
 It is made of pure unbleached longfibre sulphate pulp
 The paper fulfils the German, Dutch, CONEG and FDA regulations for papers in contact with foodstuffs
 Certified according to the quality management system ISO 9001 and the environmental management system
ISO 14001.

2018

1. Explain extrusion coating with diagram?

Ans
EXTRUSION COATING
Applications of a hot molten, diluents free high molecular weight polymer on to the surface of a moving paper
substrate using an extruder die assembly.
The steps involved are
1. Feeding the polymer and sometimes the other ingredients in to an extruder and melting them.
2. Metering the mixture at high pressure through a slotted die to form a free film.
VIVEK SINGH BASC IV

3. Drawing the film down to the desired thickness by stretching effect of the substrate running at higher speed.
4. Combining and pressing the film on to the substrate in a nip formed by chilled metal roll and a rubber
covered pressure roll.

Equipment
The equipment used for extrusion coating falls in to two basic parts
1. The extruder and die which produces and delivers a molten film to the laminator
2. The un winder, the laminator and re winder
Extruder is a heated screw type pump which supplies the molten polyethylene to the manifold of the die where it is
distributed and fed uniformly in a uniform thickness.(FIG)The molten polymer is extruded from the die and joined
with the substrate in a nip formed by steel cooling roll and a rubber pressure roll Distance between die and the nip is
5 to 9 inches depending upon material Steel cooling roll about 18 – 24 “ diameter cools the polymer to about 40 –
[Link] rubber pressure roll is usually water cooled steel roll coated with1” thick rubber.

2. Write a note on testing printability using IGT tester?

Ans
 This method describes the measuring of pick resistance of coating and printability of paper expressed as
cm/sec.
 As the printing speed increases, the forces exerted on the surface of paper increases until the fiber pick.
Significance:-
- The ability of coated paper board to withstand picking of coating or lifting of liner when printing is done.
Testing procedure (tappi 514):
 IGT ink unit :-
- Start the IGT ink unit
- It work by giving command to display
- Put the top roller down & allow for distribution of ink
- After 90sec stop distribution of ink and remove the disk roller & take it for IGT test
 IGT tester
- Place the test specimen on printing disc
- Select the accelerating speed and adjust the printing force on upper disc to 350N
- Place the inked printing disc on upper shaft
- Turn the sector into starting position
- Apply force & push both side bottom to make the print
- Lift the printing disc remove the test piece
- Determine using pick start vier and mark the start of pick or start of delimitation and report it in
m/sec

 Control
VIVEK SINGH BASC IV

- IGT can be increased by maintain SR degree minimum b/w two layer of paper board
- IGT value can be increased by starch spraying b/w the two layer to improve bonding
- IGT value can be increased by Proper loading at press section

3. What are the adhesive used in lamination?

Ans
Adhesive are divided into group that are either dry, cool or polymerize to develop a bond refer to class 1, 2,and 3
Class 1: Adhesive loses a liquid solvent, or an emulsifying medium, to develop adhesion. Water is used as solvent for
paper laminates and for other organic or organic –aqueous solvent combination are used. Water soluble adhesive
used are starch, dextrin, vegetable and synthetic gums, animal and vegetable proteins, cellulose derivatives and
silicates.
- Organic solvent solution are dispersion of lacquer ,vinyl acetate and rubber
- Emulsion adhesives are polyvinyl, synthetic rubber condensate resin and asphalt.
Class 2: adhesive are melted for application and for wetting then cooled to bond .thermoplastic waxes and synthetic
resin is used.
- In hot melt adhesive some time these are pre-applied to substrate and laminated later by heat sealing
method.
Case 3 : Adhesive develop cohesive strength through chemical activity .polymerization of the adhesive film may be
carried out by diverse influence like heat ,pressure radiation exposer to moisture vapoure absence of oxygen
combination with second ingredient or a catalyst .
Less used in lamination
Ex - Epoxy, Dimethacrylate, cyanoacrylate, polyamide etc

4. What are the industrial application of paper tube and cores?

Industry Applications

Paper Cores for winding fax rolls, telex rolls, toilet paper, newsprint, Kraft paper, etc.

Packaging Cores to wind BOPP tapes, polyester films, metalized foil etc.

Yarn carrier for POY winding, DTY winding, open-end spinning, fabric and jute winding, non-
Textile
woven fabrics, carpet yarn winding.

Thermo-couple tubes, electronic cores, civil construction, storage tubes, pyrotechnic cores and
Others
mailing tubes

5. Explain coating additives briefly, justifying their addition?

6. What is element of printing ink? Give example for each
Ans: Ink typically comprise three fundamental types of substances
1) Vehicle
2) Pigment
3) Driers - a variety of different types of additive
VIVEK SINGH BASC IV

1. Vehicle: - The ink vehicle is the fluid part of the ink that, as its name implies, transports the pigment onto the
substrate. The type of vehicle to be used in a particular ink is dependent upon the type of drying system utilized.
Acts as both medium and adhesive for pigment.
- Non-drying oil (Penetrating non drying oils)Ex : petroleum or rosin oils
2. Pigment: - The pigment is the part of the ink that imparts gloss, color, texture, and other characteristics to the
printed image. Pigments can be
 Black pigments (consisting primarily of various types of Carbon Black)
 White pigments (which are either opaque pigments or transparent pigments)
3. Printing ink additives – Driers, Bodying agents, Waxes
 Driers, which speed up the drying of inks
 Bodying agents, which increase the viscosity of an ink
 Waxes such as microcrystalline, polyethylene, paraffin, beeswax, are used to prevent such printing defects as
ink setoff and blocking, and to increase the ink's scuff resistance.
4. Other materials- Teflon, Lubricants and greases , thinner, Antioxidants and anti skinning agent, Corn starch ,
Surface active agents
 Teflon can also be added to help "shorten" an ink.
 Other compounds can be used to reduce an ink's tack.
 Lubricants and greases are added to not only reduce tack, but to help the ink distribute on the plate,
blanket, or substrate more consistently and uniformly.
 Reducing oils and solvents such as thinner can be added to increase the ink's setting capacity.

7. What are the properties and application of pulp molded products?

Ans
Property
• Excellent buffer
• Excellent sock resistance
• Delicate quality ,no deckle edge or wrinkle appearance
• No waste water and waste during manufacturing
Application of Molded Pulp Products:
• Egg trays with or without lids
• Apple trays
• Shrink wrap trays
• Bio-degradable plant pots
• Flower baskets
• Corner protectors
• Ceiling tiles
• Egg cartons (12 egg, 6 egg & 24 egg)
• Electronic packing buffers
• Fruit trays for orange, berries, avocado fruits etc
• Hospital disposables like kidney tray, urinal pots, bed pans

8. Explain aesthetic characteristic of book publishing paper?

Aesthetic/ Appearance characteristics
i) Colour
 Colour ranges from blue white to a natural shade
 Colour to be consistent throughout run
 Publisher selects specific shade which is used repeatedly for series of books over years
 Colour measuring instruments used to match shade
ii) Brightness
 Important for standard
 Contributes to grading of printability
 In evaluating two sheets equal in all respects except brightness, higher brightness will be superior
 In evaluating two sheets equal in brightness but differ in appearance, both colour and brightness are
measured
iii) Gloss
VIVEK SINGH BASC IV

 Gloss is ability of paper to reflect light rays

 Gloss is a matter of choice as some desire glossy product and others dull one
 High gloss distracts from reading and is objectionable
 National Association of State Textbook Administrators NASTA specifies minimum permissible gloss
iv) Texture
 Texture varies from super calendared to antique finish
 Special finishes may use felt marked finishes or laid finishes
 Texture helps to establish mood of reader
 Finish has secondary importance
v) Opacity
• Opacity is ability to stop light and very important property
• Paper with low Opacity allows ink backside and results in show through
• Affects attractiveness and legibility of product
• Opacity is more important in lighter basis weight under 50 lb
vi) Defects
• Dirt, holes, streaks, grease, spots, hand and foot prints and scratches not attractive
• Affect printability and runnability

9. Write a note on application and future of pulp mold?

Types of Molded Pulp Products:
• Egg trays with or without lids
• Apple trays
• Shrink wrap trays
• Bio-degradable plant pots
• Flower baskets
• Corner protectors
• Ceiling tiles
• Egg cartons (12 egg, 6 egg & 24 egg)
• Electronic packing buffers
• Fruit trays for orange, berries, avocado fruits etc
• Hospital disposables like kidney tray, urinal pots, bed pans
Future of pulp moldings
 Pulp molding is a true mass production method operating from limitless supply of low priced raw materials
 The articles produced are light, strong and serviceable
 They are not temperature sensitive
 They do not become brittle at low temperature or change shape at high temperature
 But finish and high water absorption are problems which can be improved but cost more
 As bio-degradable materials are fast replacing other alternatives in packaging, pulp molded products are
gaining popularity nowadays.
 The cost-effectiveness, design range and soft texture make it suitable to pack any materials like eggs, fruits,
etc.
 Its bio-degradability makes it eco-friendly and acceptable to any international standard.

10. What is embossing? What are types of embossing?

Embossing: Done to impart special designs with raised or depressed patterns with or without printing
Embossing Types
1. Blind Emboss
 The blind embossing process provides a clean and distinctive or subtle image on paper stock.
 It is best used to create a subtle impression or low level of attention to the piece, yet provide some slight
form of differentiation for the finished work.
2. Registered Emboss
 Registered embossing is a process that places the embossed image in alignment with another element
created with ink, foil, punching, or with a second embossed image.
3. Combination Embossing
 Combination embossing is the process of embossing and foil stamping the same image.
VIVEK SINGH BASC IV

 It involves imprinting and aligning foil over an embossed image to create a foil emboss.
 A sculptured die, generally made of brass is used for this procedure.
 The process requires close registration that must be controlled to keep the image and foil matched precisely.
 The process of embossing and foil stamping is accomplished in one operation with the use of a combination
die.
 The combination die has a cutting edge around the perimeter to cleanly break the excess foil away from the
embossed area.
4. Pastel ling
 Pastel ling is also referred to as tint leaf embossing.
 It involves the process of using a combination die to provide a subtle antique appearance to a substrate that
is embossed and foil stamped.
5. Glazing
 Glazing refers to an embossed area that has a shiny or polished appearance.
 Most often this process is accomplished with heat that is applied with pressure in order to create a shiny
impression on the stock.
6. Scorching
 Scorching is similar to glazing except that it is not used to polish the stock.
 Instead, scorching does what it implies: as the temperature of the die heating plate is increased beyond a
normal temperature range, a scorched effect is created in the embossed image, which results in an antique
or shaded appearance
11. Write a note on types of flutes?
 Corrugated board comes in different thicknesses, depending on the height of the flutes, and number of
flutes per foot, as follows:
 Different types of corrugated boxes are designated by the letters A, B, C, E, or F. The most frequently used
flute corrugation is C flute, with 80% of boards and boxes making up this designation

1. Type A
- Type A has excellent compression and cushioning as well as good stacking strength.
- It is great for packaging breakable items and is commonly used for structural strength.
2. Type C
- Type C makes a good printing surface. It also has compression properties and offers crush
resistance.
- It is most commonly used for shipping boxes and to secure glass, furniture, food, etc
3. Type B
- Type B has excellent crush and puncture resistance and is a great printing surface.
- This is commonly used for inner packaging components such as pads and partitions.
4. Type E
- Type E thin construction helps to reduce storage space. It has excellent crush resistance and an
exceptional printing surface.
- It is commonly used for displays, pizza boxes, ballot boxes, and packaging of consumer goods
such as glass, ceramics, and cosmetics.
5. Type F
- Type F has an outstanding printing surface and excellent crush resistance. Its thin construction
allows for stiffer boxes with less fiber.
- It is commonly used in fast food clamshell containers and packaging for consumer goods such as
cosmetics, jewelry, and shoes.
12. what are the functional; test carried out on packaging?
VIVEK SINGH BASC IV

FUNCTIONAL PERFORMANCE TEST

1. DROP TEST:
This test should assess the ruggedness of the secondary packaging and its ability to protect the primary
packaging and product from damage. It should simulate the effects of sorting machines, conveyors, and
manual handling and stacking that may result in short, sharp vertical drops.
2. INCLINED IMPACT
This test should assess the ability of combination packaging to withstand side impacts, such as those
associated with manual handling and sudden starts and stops during vehicle or train transit.
3. PEST PREVENTION
This test should assess the ability of the packaging to prevent pest damage that may be caused by rodents,
insects or micro-organisms to primary packaging or the product.
4. COMPRESSION STRENGTH
Test should simulate the temporary compression associated with stacking during transport and distribution.
5. STACK LOAD
This test should assess the stability of the combination packaging and packaging adhesives under
compression associated with long-term storage or warehousing.
6. WEATHERING
This test should assess the ability of combination packaging to withstand changes in temperature, moisture,
and direct sunlight exposure associated with transport and storage.
7. VIBRATION
This test should assess the ability of packaging to withstand vibration associated with transport.
8. DISASSEMBLY
This test should assess the disassembly of combination packaging for the purpose of recycling the
component materials.
9. RECYCLABILITY
This test should assess the sustainability of all the component materials used in the combination packaging.
10. COST EFFECTIVENESS
This test should assess the cost of the packing as a percentage of the cost of the product inside the
packaging. It should make an effort to estimate the direct costs that would be incurred over the life cycle of
the combination packaging.
13. list the paper and ink related problem faced in printing?
Ans: paper related
1. Mottle
2. Misregister
3. Dimensional stability
4. Plate blinding
5. Setting and Drying
6. Contamination
7. Fibers
8. Hickeys
9. Loose surface dust
10. Picking
Ink related problem:
1. Bloom
2. Bleeding
3. Crazing
4. Toning
5. Blushing
6. Scumming
7. Desensitization
8. Tinting
9. Haze
14. Write note on method of drying of printing ink?
VIVEK SINGH BASC IV

15 what are advantage and disadvantage of paper/paper board in packaging?

Advantages disadvantage

Mechanical strength. Porous, Opaque

biodegradable Poor barrier properties to O2, CO2

good printability Loss of flavor components from foods.

cheap no heat sealed

Coatings done to improve barrier properties easily torn

Suitable for use in microwave ovens Cannot be co-extruded

16. What is the resilient material used in packaging?

Ans
Resilient material is used to provide cushioning effect whose function is to provide protection from physical and
mechanical damage to items.
a) Rubberized hair, rubberized coir, poly styrene and polyurethane foams, springs, metal shock mounts, etc.
b) Non-resilient system - rigid foams, honeycomb, etc.
c) Reinforcements - straps - steel, plastic, rayon-based & wires, bailing hoops etc.
d) Stitching methods - bags / paper and textiles, corrugated board boxes and stitching appliances.
e) Seals and closures.
f) Lining compounds and lacquers for tin containers.
 VIVEK SINGH BASC IV

g) Labels and labeling including instant labels

17. What is plate bending? What are the cause and remedies?
Description
The image area of the plate progressively looses its receptivity to the ink. This tends to occur first in the highlight
areas
Causes
1. Plate making is not proper
2. Detergent has in filtered the dampening system
3. The fountain solution is poorly balanced or improperly formulated
4. Plate cleaners or scratch removers have not been completely rinsed from the plate
5. Paper is depositing filler, coating or lint on the blanket affecting the plates
6. Ink is not properly formulated, particularly if it occurs in the magenta unit(due to excessive calcium)
7. Blanket is either over packed or loose
8. Ink is contaminated
Possible solution
1. Try new plates
2. Rinse thoroughly all parts of the dampening system in contact with detergent
3. Fountain solution(may be too acidic) need to be adjusted for pH balance
4. Avoid using excessive amounts of plate cleaner or scratch remover
5. Use less abrasive paper
6. Check all rollers for condition and setting
7. Check packing of blanket and blanket wrapping tension
8. Check materials such as paper, ink and solvent and check overhead structure for foreign materials that may
be dropping on to the press
18. Write notes on parchment paper?
 In addition to moisture resistance, parchment papers complete greaseproof .
 It is thus mainly used for packaging greasy or oily or grease -sensitive products.
 Glassine and imitation parchment paper have similar grease - repellent properties.
 Parchment paper is water resistant and greaseproof.
 It is used to wrap and protect products that are oily or that may leak.
 It is also used to wrap products that are sensitive to grease leakage.

Answer the following questions briefly

[Link] RFID and SWMA
Ans.
SWMA-The Standards of Weights & Measures Act
FRIED-Radio-frequency identification

2. How base sheet properties affect coating?

Ans
 Smoothness is primarily affected by the base sheet
 A coating will not hide most base stock problems
- Color and brightness
- Flaws i.e. hardwood vessel segments
 Print quality is function of base sheet and coating
 Non-uniform sheet can lead to print mottle
3. What are the types of lamination?
Ans
Types of lamination
1. Solid fiber laminating – Several plies joined
2. Sheet lining – Better quality paper/board to lower quality paper/board
[Link] sheet laminating – Glassine, grease proof, coated sheet for special properties
4. Combination – Metallic foils, synthetic films to give unique properties
5. Converting operation – Formed products laminated
 VIVEK SINGH BASC IV

4. What is the base stock used for pulp molding?

Ans :
 Kraft, ground wood, rayon cotton linters, sulfite, newsprint, waxed papers and glass etc

7. What is right sizing in packaging?

8. What are the details printed on a paper ream?

9. What is scumming? What are the causes and remedies?

Ans
In offset lithography, scumming is a generic term for the presence of ink on non-image areas of the printing plate, which
can be caused by a variety of press conditions, in particular the use of a fountain solution that is too acidic, where the
solution begins to eat away at the surface of the metal plate and its protective coating.
Causes: poor ink strength , poor plate development ,too much ink or not enough water
Remedies: proper plate setting and good quality of plate ,proper manufacture of ink solution

10. What is aseptic packaging?

11. Define Tg (glass transition temperature) of binder.

Ans.
It gives information about softness or harness of polymer film. Lower the Tg value, softer is polymer.

[Link] FSSAI and NASTA

Ans
FSSI- Food safety and standard authority of India
NASTA-National Association of State Textbook Administrators

13. What properties are important for laminating adhesive?

 Rapid and uniform wetting and uniform application
 Low viscosity and better flow
 Less thickening and gel formation – easy and better application
 Good tack and proper setting
 Too fast drying opens up and slow setting – de lamination
 Good stability on use and storage

14. What are dispersants in pigment coating? Give two examples.

15. What is the future of pulp molding?
16. What is the significance of packaging?
[Link] is one planet living
18. What are the components of printing ink? What is purpose of their addition?
1. Vehicle -fluid part of the ink that transports the pigment onto the substrate.
2. Pigment- The pigment is the part of the ink that imparts gloss, color, texture, and other characteristics to
the printed image
3. Driers -which speed up the drying of inks

20. Calculate the power consumption to disperse 2MT of clay with following data Current - 85 Amps, Volts - 410v, Cos
Ø - 0.85, dispersion time - 90minutes, clay - 2MT
22. What are strategies for sustainable packaging?
- renewable, sustainable resource
- can be reused and recycled
- Helps to reduce waste.
 VIVEK SINGH BASC IV

23. Calculate the coating solution requirement on dry basis (MT) with following data. Required coat weight - 11gsm,
manufacturing order - 120MT, gsm of paper – 300
24. What are the steps involved in paper lamination process?
Ans
STEPS OF LAMINATION
i) Applying the adhesive
ii) Combining the plies
iii) Setting the adhesive

26. What are the advantages and disadvantages of sodium silicate in corrugating?
Ana
Sodium silicate has following advantages
- High solid content
- Rapid setting rate
- Strong adhesive quality
-Finished product with sodium silicate has
i) Smooth surface
ii) Maximum strength and caliper
Disadvantages of sodium silicate are
- Leaves hard glassy deposits on the machine
- Does not produce water resistant bonds needed for cold storage and damp vegetable packing

27. What is brick carton?

28. What are Printability and Run ability characteristics required for book publishing papers?
Ans.
1. Failure of sheet to hold its size and shape
2. Physical Strength requirements
 Tearing, stretching, bursting, bending and folding
3. Strength requirements
 Internal bonding, surface strength to avoid blanket contamination, de lamination and blisters
4. Cleanliness requirements
 Foreign material, slitter dust, lint, scale, any loose material may fall into ink tray
5. Variation in slipperiness
 Causes folder jam ups and leads to handling problems
6. Out of square paper during trimming
 Causes, miss register and further complicates binding work.
8. Good mechanical roll conditions
 May lead to defects like calendar cuts, bursts, wood shives, cracked edges, fiber cuts, slime holes, slack area,
poor winding

30. What do you understand by customer demand?

 Higher productivity - Lower cost
- Higher speed
- Less breaks
- Less wash-ups
 Higher print quality
- Good reproducibility
- Excellent contrast

32. Define flat crush test. What is its importance?

34. What are dispersants in pigment coating? Give two examples.
35. How is native starch different from oxidized starch?
36. How are paper cones classified?
37. What is labeling?
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40. What is VCI paper? Where is it used?

Ans.
VCI paper (Volatile Corrosion Inhibitor)
 VCI paper provides protection from corrosion.
 The paper acts as a support for the inhibitors which actually provide protection from corrosion.

41. Why surface sizing treatment depends on type of paper being made?
42. Differentiate between IGT and wax pick test.
43. What are dispersants in pigment coating? Give two examples.
44. What is laminating? What are types laminations used?
45. Calculate the power consumption to disperse 1MT of clay with following data Current - 85 Amps, Volts - 410v, Cos
Ø - 0.85, dispersion time - 60minutes, clay - 2MT
46. What are the points to be checked on corrugating machine?
48. What is labeling? What are its uses?
49. What is one planet living
50. What are the factors affecting print quality?
Ans.
Affected by:
•Printing method
•Printing machine
•Ink
•Paper
•Environment (RH and temperature)
•Operator

51. List the variables affecting size press pick up.

52. How is binder different from cobinder?
53. Define ring crush test. What is its importance?
54. What is laminating? Where are laminates used?
55. Mention four important additives of coating solution.
56. Define packaging. What is right sizing in packaging?
57. What are the benefits of using edge protectors?
58. How are coated papers classified?
59. What are the steps involved in printing ink manufacture?
50. What are the environmental factors affecting paper properties?
51. Define RFID and SWMA
52. Define flat rust test .what is its importance?
53. What are the steps involved in paper lamination process?
54. What is antioxidant used in pigment coating? Give two examples?
55. How are pulp molding classified?
56. What is edge protector? Why they are used?
57. What is labeling?
58. What are requirement of duplicating papers?
59. Define dot matrix printing
Ans
 In this Information is gathered and transmitted using digital signals is efficiently converted in to hard copy
with non impact dot matrix printing systems

60. What is contamination with respect to printing? What are the causes?
Ans.
Contamination is a print interference that results in non print areas or specks in printing. The shape of the void is a
Clue to the cause of the void
Causes
1. Ink hickeys doughnut shaped voids are caused by material carried by ink and the particles originate from paper.
2. Pick outs and coating lumps are agglomerates of fiber
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3. Coating pick or picking results from the tack of the exceeding the cohesive or binding strength of the coating
Materials
61. What is Dispersent in pigment coating? Give two examples?
Ans. Example – Polyphosphates, Lignosulfonates, Silicates
Function
- Dispersent are low molecular weight material that are absorbed to pigment surface proving enhanced
stability by keeping the particle associating to each other
- It is used to disperse pigment to achieve minimum viscosity at high speed disperse rate

62. How is native starch different from oxidized starch?

63. How is paper cones classified?
64. What are the causes for mottle?
65. Define nip rejection and film splitting
Ans. Nip rejection: In conventional size press size solution is delivered to the nip forming a pond above the nip .If
hydrodynamic forces are too great; this upward velocity causes the solution to break the surface of the pond and
splash out of the nip
Film splitting: during sizing most of the size solution is absorbed into the sheet excess solution remains on the
surface of the sheet between paper and roll and at the exit of the nip this film is split into two layers with part
following the web and the rest remaining on the roll surface

64. What is trap with respect to printing?

Trap is a measure of the ability of a wet ink film printed on the paper to accept the next ink printed on top of it.
Preucil’s formula is used to measure trap.
% Trap = {(Density of overprint – Density of 1st ink)/Density of 2nd ink} x 100

65. What is the base stock used for pulp molding?

66. What is right sizing in packaging?
67. What is detail given on paper ream labels?
68. What is waterless lithography?
 Ans. It is process which eliminates water in lithography where a silicone coating is used to cover the non
image areas of the plate to prevent ink pick up in these areas.
 The image area is created photo mechanically by removing the silicone coating

69. What is grain direction?

Ans
• Grain or machine direction is formed during formation of the paper on the wire. Fibers become oriented in
the machine direction, and only a few portion in the cross direction.

70. What is aseptic packaging?

71. What is ink length?
72. What are paper laminates?
Definition – Process of combining of like/unlike substrates with adhesive.
- To improve appearance
- To improve strength
- To improve utility (usefulness
74. What are advantages and disadvantages of calendaring coated paper?
Ans.
ADVANTAGES DISADVANTAGES
• Closes surface • Opacity reduction
• Smoothness • Brightness drop
• Gloss Improvement • Closes surface
• Cost
• Surface Defects
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• Gloss Mottle

75. Why is paper versatile material for packaging?

Ans. Paper and board are versatile material for packaging because it is durable ,reliable material that perform well no
matter what its contents .from medical to frozen food packaging ,milk cartoon to shoebox can be used and designed
to meet need of wide range of product .

76. What is liquid packaging board?

Ans. Liquid packaging board is multi-ply paper board with high stiffness, strong wet sizing and barrier coating e.g.
plastic.

77. What I one planet living?

Ans. the phrase ‘one planet’ refers to the level of natural resource use required for everyone on the planet to have
access to their ‘fair share’. Today, a small number of people use the majority of the earth’s resources.

78. What are requirements for folding cartons?

Ans .requirement is puncture resistance, tensile strength, stiffenes and printability and if it is used for liquid storage
then water proofing is done by coating.