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We respond to the customers' diversified and sophisticated needs with the integrated manufacturing system from printing to producing and processing bags.
Gravure printing
Gravure printing is a kind of intaglio.
It suits the printings like photographs required to reproduce subtle tones exact and beautiful.
It also can be printed fast so used to print the packages of various products which require large printing at one time.
Photographic pages in the magazines are still called ‘gravure’ because they used to be reproduced with this technique.
The procedures of gravure printing are:
  • The ink goes into the hollows called ‘cells’ which are on the surface of the gravure cylinder.
  • The ink on the nonprinting area of the printing plate is wiped off with the doctor blades.
  • The film or paper which would be printed is put between the plate and the impression roll and pressed. The ink is transferred from the cells to the film (paper).
  • The film or paper is sent through the dryer to dry the ink.
  • The film or paper is sent to the unit of another color.
These procedures are repeated as the numbers of the colors.
Fujiko pursues the capacity of gravure printing to realize reproducing more detailed and beautiful printings.
Color reproduction

The color printing including gravure printing basically reproduces the colors with the four colors – cyan (blue), magenta (red), yellow and black.
The primary colors are three as showed in the right figure – cyan (blue), magenta (red) and yellow.
When you mix all the three colors you can get a ‘color like black’ but not true black. So besides them black ink is used.
We call those colors ‘CMYK’ which stands for Cyan, Magenta, Yellow and Key Plate(black). The printing technique reproducing various colors with these four colors is called ‘process printing.’
Process printing reproduces the colors according to the quantity of area which each color’s dots occupy.
The deepest colors have solid printed area and the light colors have smaller dots. Most of the colors can be reproduced with the process printing.

Spot color

There are colors which are difficult or impossible to reproduce.
Process printing has limits like that it can’t reproduce deeper colors than solid printing or has difficulties to reproduce very light colors with the dots. And there are colors which are difficult to be reproduced clearly when the colors with same shade overlap in the process printing.
For example vivid orange or green, purple, light pink or lavender are the colors difficult to be reproduced. So do metallic colors like gold or silver and fluorescent colors.
The ink which is mixed to reproduce the colors which are enable to be reproduced with the process printing is called ‘spot colors.’

Gravure cylinder

Gravure cylinder is an essential part for rotogravure.
It’s an iron cylinder coated with copper onto which the image of each color is engraved. The surface is finished with chrome to make the engraved images everlasting. The durable engraved cylinders are necessary for mass and rapid gravure printing.
There are some types of engraving methods. The methods often used nowadays are ‘electromechanical engraving’ which engraves the cupper surface directly with a stylus and ‘chemical engraving’ which jets chemical liquid to the cupper surface processed specifically to form cells.
It is no exaggeration to say that the quality of the finish of gravure printing relies on the quality of the cylinder engraving.

Computer Color Matching (CCM)

The computer scans the targeted color chart and calculates the most suitable colors and composition using preregistered ink to mix ink. Small amount of ink is made on the basis of the calculation and checked the finished color by a printability tester before actual printing.
It can mix the ink to get the desired color in short time without depending on the skills or intuition of the printing operator and prevent much ink from being wasted as a result of failure of mixture.
It’s also good for environment because wasted ink is industrial waste.

Recycled solvent

A solvent recycling system has introduced to Fujiko.
Solvent is extracted with the system from surplus ink as much as possible.
The extracted solvent is used to remove ink from jigs and cylinders and brings an efficient usage of resource and a reduction of industrial waste.

Bag producing -- how the bags with handling holes for toilet and diapers are made.

Sealing is the first procedure to make the bags of the polyethylene film after printed. A sheet of film is fold into half and as soon as it is cut into the necessary width by the high temperature slit blade the cut edges are adhered.
After this procedure the film is a very long rolled cylinder.
If the edges are bad adhered, for example there is a pinhole, the bags don't have enough strength and may be broken.
The procedure looks like very simple but actually a very deep one which contains much know-how to produce secure products.

The gusset parts of the sides of the bags are formed.
The cylinder formed film after the sealing procedure is ballooned with air, goes through the specific cylinder of folding shape and is rolled again.
The bags with gussets can contain the things much better than the ones without.
And when the bags are laid flat the ones with gussets have bigger capacity than the ones of same size without gussets.
Unless the folding position fits to the printed image well, the bag looks very bad. So the definition of the folding position is important.

This is the last procedure. A high temperature sealing bar is pressed to the cylinder formed film with gussets to make handling holes. There are various forms of sealing bars; one big hole for handling, two small holes, etc. This is a complicated procedure requiring very careful operation to make sure the pressing of the seal bar, the application of the heat or the finishing condition of each cut edge right. Although this is a difficult procedure a failure should not be allowed for the bags produced thousands per day. We never stop making effort with innovation of technology and thorough abidance by the operation manuals to offer the customers reliable products.
We can offer various film processing besides above.
Please contact us to consult about the types of processing and the standards.
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