MACHINERY REQUIREMENT PLAN FOR TIN CANS &

OFFSET PRINTIG




TUFFLINELTD

October 6, 2011
KULATHUNGA H.G.G.
CONTENT

1.0 INTRODUCTION 01
2.0 TYPES OF CANS AND THEIR USES 02
3.0 TIN CAN MANUFACTURING PROCESSES 03
4.0 THREE PIECE TIN CAN MANUFACTURING PROCESS 04-05
4.1 MACHINERY REQUIREMENT 06
4.2 THREE PIECE CAN MAKING PRODUCTION LINE 01 06
4.2.1 QUOTATIONS 07-08
4.2.2 MACHINE INSTALATION PLAN FOR CAN BODY 09
4.2.3 MACHINE INSTALATION PLAN FOR CAN END 10
4.3 THREE PIECE CAN MAKING PRODUCTION LINE 02 11-12
4.3.1 QUOTATIONS 13
4.3.2 MACHINE INSTALATION LAY OUT 14
5.0 DRAW AND IRON CAN MANUFACTURING PROCESS 15
5.1 MACHINERY REQUIREMENT 15-16
6.0 OFFSET PRINTING 17
6.1 APPLICATIONS 17
6.2 ADVANTAGES 17
6.3 OFFSET PRINTING PROCESS 17
6.4 MACHINERY REQUIREMENT FOR CARTON PRINTING 18
6.5 TECHNICAL PARAMETERS OF SELECTED MACHINE 18
6.6 QUOTATIONS 19
6.7 MACHINE INSTALATION LAYOUT 20


1.0 INTRODUCTION

TIN CANS
A tin can, tin, steel can, or a can, is a sealed container for the distribution or storage of goods,
composed of thin metal. Many cans require opening by cutting the "end" open; others have
removable covers. Cans hold diverse contents: foods, beverages, oil, chemicals, etc.
Tin can industry is a vast industry; there are several types of cans and can making processes. In this
project mainly focused on to prepare a machinery requirement plan for tin cans for food and
beverage industries.
OFFSET PRINTING

Offset printing is a commonly used printing technique in which the inked image is transferred (or
"offset") from a plate to a rubber blanket, then to the printing surface. When used in combination
with the lithographic process, which is based on the repulsion of oil and water, the offset technique
employs a flat (planographic) image carrier on which the image to be printed obtains ink from ink
rollers, while the non-printing area attracts a water-based film (called "fountain solution"), keeping
the non-printing areas ink-free. Also offset printing is used in lot of applications such as newspapers,
magazines, brochures, stationery, books and etc. But this project is focused on to find out the
machinery requirement for carton printing.










2.0 TYPES OF CANS AND THEIR USES

TABLE NO 01 TYPE OF CANS AND THEIR USES

PROCESS

MATERIAL USED

PRODUCTS CONTAINED

Three piece

Steel
Food, juices, spices, aspirin,
& other non-food items such
as paints and glues (includes
decorative tins); includes
aerosols


Draw & iron

Aluminum (1- and 2-piece)
2-piece: primarily beer,
carbonated beverages, juices
1-piece: aerosol & pump
products (perfume, air
freshener, saline solution);
fuel additives

Steel (2-piece only)

Food, other non-food items

2-piece draw/redraw

Steel, aluminum

Food, shoe polish, car wax,
other non-food items

Ends

Steel, aluminum

All (except 1-piece draw &
iron)

Crowns and closures

Steel


Food & non-food items


3.0 TIN CAN MANUFACTURING PROCESSES








TIN CAN
MANUFACTURING
PROCESSES
3-PIECE CAN BODY
MAKING PROCESS
2-PIECE CAN BODY
MAKING PROCESS
DRAW AND IRON
PROCESS
DRAW REDRAW
PROCESS
CAN LID MAKING
PROCESS
CROWNS AND
CLOSURES
MAKING PROCESS
4.0 THREE PIECE TIN CAN MANUFACTURING PROCESS
3 Piece can making process can be categorized into to two groups,
1. Can body manufacturing process
2. Can end manufacturing process

CAN BODY MANUFACTURING PROCESS



STEEL
COILS OR
PLATES
SLITTING
BODY
SHAPE
FORMING
SEAM
WELDING
OR
CEMENTIN
G
COATINGS
& DRYING
FLANGING
SEALING
CAN END MANUFACTURING PROCESS








TIN COILS
OR PLATES
SLITTING
PUNCH
FORMING
EDGE
CURLING
LINING
DRYING
4.1 MACHINERY REQUIREMENT
1. FOR CAN BODY MANUFACTURING

1) Slitter machine
2) Body forming machine
3) Seam welding or cementing machine
4) Coating and drying machine
5) Flanging machine
6) Sealing machine


2. FOR CAN END MANUFACTURING

1) Slitter machine
2) Punch machine
3) Curling machine
4) Ling coating machine
5) Drying machine
The above mentioned machineries require for a three piece tin can making line.
4.2 THREE PIECE TIN CAN MAKING PRODUCTION LINE 01
This is an automated production line for three piece tin cans.

MACHINERIES FOR CAN BODDY MACHINERIES FOR CAN END
Auto Duplex Slitting Machine
Powder spray coating machine
Auto welding machine
External Coating & Conveying
Machine
Induction drying machine
Conveying machine
Flanging\beading\seaming\Necking 3-
station combo machine.
Conveying machine
Auto sheet feeder machine
CNC feeding system
Auto scrap collection machine
Pressing machine 45T
Conveying Machine
Curling Machine
Conveying Machine
Lining & Drying Machine

Maximum production capacity of the production line = 150 cans/min

Total cost of the machines for can body making = $ 387,400
Total cost of the machines for can end making = $ 145,000
Therefore total cost for machines = $ 532,400

4.2.2 MACHINE INSTALATION PLAN FOR CAN BODY

4.2.3 MACHINE INSTALATION PLAN FOR CAN END

4.3 THREE PIECE TIN CAN MAKING PRODUTION LINE 02
This is a semi automatic production line for three piece tin cans.
1.0 SEMI AUTOMATIC PRODUCTION LINE FOR CAN BODY


EQUIPMENT NAME

QUANTITY
Slitter(GT1B5) 2
Roll forming machine(GT3A3) 1
Seam welding machine(FN2000-B) 1
Coating & drying machine(GT200U) 1
Flanging machine(GT3TB20)
(for 8500 ml)
1

Flanging machine(QYA180F)
(for 400 ml)
1

Sealing machine(GT4A16B) 2

2.0 SEMI-AUTOMATIC PRODUCTION LINE FOR CAN LID


EQUIPMENT NAME

QUANTITY
40T Punch machine 1
25T punch machine 1
Curling machine (GT2B3) 1
Ling compound machine (GT2C3) 1
Drying machine (GT2D5) 1
Dies for 8500 ml 1(2pieces)
Dies for 400 ml

1(2pieces)


PRODUCTION CAPACITY & OTHER DETAILS OF MACHINES
EQUIPMENT CAPACITY POWER
(kW)
DIMENSIONS
(L*W*H)
Slitter(GT1B5) 1.1 1500*1600*1105
Roll forming machine(GT3A3) 80cans/min 0.25 700*400*840
Seam welding machine(FN2000-B) 25-
50cans/min
15kVA 1350*1300*1700
Coating & drying machine(GT200U) 6-30m/min 10 9600*680*1460
Flanging machine(GT3TB20) 15cans/min 4 1300*700*1750
Flanging machine(QYA180F) 15cans/min 400*500*1380
Sealing machine(GT4A16B 15-
30cans/min
1.5 750*530*1980
40T Punch machine 2.2
25T punch machine 4
Curling machine (GT2B3) 0.37
Ling compound machine (GT2C3) 50-
160cans/min
990*700*1500
Drying machine (GT2D5) 1500-3000
pcs/hour
28.3 6440*1000*1800

Total cost for machines = $ 106900

Maximum production capacity of this line = 15cans/min


5 DRAW AND IRON CAN MAKING MANUFACTURING PROCESS

5.1 MACHINERY REQUIREMENT
Cupper machine
Wall ironer machine
Trimmer machine
Washer machine
Printing machine
Necker and flanger machine
This process is a huge expensive process and also all 2-piece can making machines are manufactured by
USA, British and Germany. Also most of these machines are purchased from America at 30,000,000USD
a line. Therefore the following process can be used for manufacturing beverage cans.

ALUMINIUM
COIL
CUPPER
WALL
IRONER
TRIMMER
WASHER
DECORATION
NECKER AND
FLANGER


Above shown beverage cans are manufactured by using three piece can manufacture process. This
process is not a big investment at the beginning. Therefore 3 PIECE beverage can is fit for the starting.
But in this process using tin plates, tin plates are little expensive than aluminum. It is a disadvantage of
this process.
For making three piece beverage cans as shown in above can be used the machineries which are
mentioned under the topic THREE PIECE TIN CAN MAKING PRODUCTION LINE 01 by changing
the mold.






6 OFFSET PRINTING

Offset printing is a commonly used printing technique in which the inked image is transferred (or
"offset") from a plate to a rubber blanket, then to the printing surface. When used in combination with the
lithographic process, which is based on the repulsion of oil and water, the offset technique employs a flat
(planographic) image carrier on which the image to be printed obtains ink from ink rollers, while the non-
printing area attracts a water-based film (called "fountain solution"), keeping the non-printing areas ink-
free.
6.1 APPLICATIONS
News papers
Magazines
Brochures
Stationery
Books
6.2 ADVANTAGES
Consistent high image quality.
Quick and easy production of printing plates.
Longer printing plate life than on direct litho presses.
Offset printing is the cheapest method to produce high quality printing in commercial printing
quantities.


6.3 OFFSET PRINTING PROCESS





6.4 MACHINERY REQUIREMENT FOR CARTON PRINTING LINE


Printing machine
Slitter machine
Die cutter machine
Stacker machine
Total cost for the machine = $ 243,300.00
6.5 TECHNICAL PARAMETER OF MACHINE


APSII
Items

AFPS-1600x2800
Max. machine speed of
lead edge feeder (p/min)
180
Recommended speed
(p/min)
120-150

Max. feeding size (mm)

1600x2800
Min. feeding size (mm) 400x650

Skip feeding (mm)

1800x2800

Max. printing area (mm)

1550x2750
Printing precision (mm)
0.5
Printing plate thickness
(mm)
7.2
Min.
slotting
space
Normal knife
(mm)
Reverse knife
(mm)
180x180x180x180
360x80x360x80
Max. slotting depth (mm) 350
Slotting precision (mm)
1


Shanghai Lucky Spring Packing Technology Development Co.,
Ltd.
Add: 728 Room, Kaicheng Building, No.135 Longcao Road, Xuhui,Shanghai, China.
Tel: +86-21-61212752/86- 15900674412 Fax: +86-21-61213230

QUOTATION

AFPS Computerized Flexo Printing Slotting Rotary Die-cutting Machine

Unit priceunitdollar
16002800mm
FOB Shanghai, China
Four colors printer +slitter+ Die cutter
+ stacker
ALL PRICE:
48600+29100x4+34100+33200+11000
=243,300.00 USD

Feeding Unit 48600
Printing Unit (Each Unit) 29100
Slotting Unit 34100
Die Cutting Unit 33200
Stacker 11000


COMMERCIAL CONDITIONS:
Loading port Shanghai
Destination port at buyer's option
offer validity This offer is valid for 1 months
delivery period: Manufacturing period is about 60-90 days upon receipt of prepayment.
Standard payment terms
- 30% pre-payment
- 70% after manufacturing at the factory
Round tickets, board and lodging expenses of specialists shall be covered by the customer.
Also Buyer pays 70 US dollars per day for each expert.
The period of warranty for normal operation of the Equipment is 12 (Twelve) months from the
Date of putting it into operation, which does not include easily wearing parts and human factor.

Packing: Stand steel pallet

REF.No. 23092011
TO Mr. Gayashan Kulathunga
Contact person: Cherry
TEL TEL+86-21-61212752 / 86-15900674412
FAX FAX+86-21-61213230
E-mailgkulathunga@gmail.com Date 23/09/2011