Company Overview
A leading flexible packaging company involved in rotogravure printing uses approximately 4 tons of poly film per production batch. In each batch, the company uses a combination of ink and solvent, with an ideal 60:40 ink-to-solvent ratio to maintain proper viscosity and print quality.
The Challenge
Despite having a defined ink-solvent ratio, operators noticed frequent fluctuations in the viscosity, with the ratio often drifting towards:
• 70:30
• Even 80:20 (ink-heavy)
These shifts were not always caught in real time due to viscosity being manually monitored, leading to:
• Overuse of ink and solvent
• Inconsistent ink flow and color
• Higher printing costs
The company estimated that for every 4-ton batch of film, approximately ₹5,00,000 worth of ink was being consumed.
The Solution – Inline Viscometer Integration
To bring better control over the printing process, the company implemented an inline viscometer system and Ink Viscosity Controller. This device continuously monitors and adjusts the ink viscosity in real time, ensuring that the correct ink and solvent levels are maintained throughout the run.
Key Outcomes
After installing the viscometer, the company experienced:
• Stable ink-solvent ratio at 60:40
• No more drift to 70:30 or 80:20
• 30% reduction in ink usage
With ink costs averaging ₹5,00,000 per 4-ton batch, this resulted in cost savings of approximately ₹1.5 lakhs per batch.
Benefits
• Cost savings:30% reduction in ink expenses
• Consistent print quality due to stable viscosity
• Improved operational efficiency
Conclusion
By adopting a viscometer for viscosity control, the company not only improved its ink-solvent ratio accuracy but also achieved significant cost savings and better process control in its rotogravure printing operations.
