Course Title: Manufacturing / Production Operation in Flexible Packaging

     

    Course Duration: 2 Days / 6 hours per day

    Format: Combination of PowerPoint lectures, Q&A sessions, live case discussions, and group activities.

    Course Objectives:

    • To provide comprehensive knowledge of the production operations involved in flexible packaging manufacturing.

    • To familiarize participants with key machinery and technologies used in each production stage.

    • To understand production workflows, operational parameters, and quality checkpoints.

    • To explore troubleshooting and efficiency improvement techniques in production lines.

    • To build awareness on safety, maintenance, and sustainability practices in manufacturing operations.

    Target Audience:

    • Production supervisors and operators in the packaging industry.

    • Technical and engineering staff working in flexible packaging plants.

    • QA/QC professionals seeking to understand production workflow.

    • Procurement, planning, and operations personnel.

    • New recruits and trainees in flexible packaging companies.

    Day 1: Introduction & Pre-Press to Lamination

    Overview of Flexible Packaging Manufacturing Workflow:

    • Step-by-step production stages.
    • Key performance indicators (KPIs) in production.

    Extrusion & Film Blowing Process:

    • Types of extruders used.
    • Key parameters: temperature, pressure, film thickness, width control.
    • Common defects and troubleshooting.

    Printing Operations (Rotogravure/Flexographic):

    • Printing principles and technologies.
    • Ink systems and viscosity control.
    • Registration, drying systems, and defect control.

    Lamination Process:

    • Types of lamination (solvent-based, solventless, extrusion lamination).
    • Laminator components and functions.
    • Monitoring bonding strength and adhesive curing.
    • Common issues and process optimization.
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    Day 2: Finishing to Quality Control

    Slitting and Rewinding Process:

    • Purpose and process parameters.
    • Slitter types and blade adjustments.
    • Reel winding quality and defect elimination.

    Pouch/Bag Making Operations:

    • Types of pouches: 3-side seal, center seal, stand-up pouch, zipper pouch.
    • Sealing parameters: temperature, dwell time, pressure.
    • Machine setup, format changeover, and quality assurance.

    Production Planning and Process Optimization:

    • Order scheduling and machine utilization.
    • Downtime analysis and waste minimization.
    • Lean manufacturing practices.

    Safety, Maintenance & Sustainability in Production:

    • Standard safety protocols and equipment handling.
    • Preventive maintenance practices.
    • Sustainable production and energy efficiency.

    Group Activity and Final Assessment:

    • Simulate a production line setup for a new flexible packaging job.
    • Identify potential challenges and propose solutions.
    • Presentation and discussion.
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    Course Materials:

    • Course workbook on flexible packaging production.

    • Process flowcharts and machinery datasheets.

    • Troubleshooting guide for common production issues.

    • Case studies from actual flexible packaging plants.

    • Access to videos and industry reference materials.

    Evaluation and Feedback:

    • Daily quizzes and session recap activities.

    • Final day group assignment and peer review.

    • Instructor and participant feedback forms.