Description
Course Details
- Online Training Hours: 75 hours
- Live online classes with the instructor
- Duration: 4 months
- Start date:
- Eligible for FUNDAE funding (Spain)
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Advanced Converting Program
Objectives
Acquire the knowledge required to manufacture corrugated boxes correctly.
Understand every machine section involved in printing corrugated board, including printing methods, plates, ink regulation systems, prepress, and high-quality printing.
Understand in detail the machine components required for rotary or flat die cutting and box folding, together with the manufacturing process in each machine.
Understand each process area in depth and learn to analyze, detect, and resolve day-to-day production problems.
Methodology
The course can be delivered online or in a blended format. The online program combines recorded video modules, live classes with the instructor, practical case resolution, and assessment exams.
Scheduled live online sessions take place throughout the modules to address cross-cutting topics, resolve proposed cases, and give participants the opportunity to raise questions and discuss specific situations.
Attendance at these sessions is mandatory.
Full Course Syllabus
01.- Corrugated board as a structure
- Definition and general characteristics
- Structural characteristics
02.- Printing
- Types of printing
- Flexographic printing
03.- Inks
- Ink components: pigments
- Resins
- Alkalizing agents and antifoam agents
- Ink kitchen
- Machine-side elements required during production
- Machine-side elements: wetting agents
- Rheology, thixotropy, and viscosity
- pH
- Viscosity control
- Dot gain
- Color
- Three-color and four-color printing
04.- Anilox rolls
- Metal anilox rolls
- Ceramic anilox rolls
- Cell shapes
- Line count, volume, cell dimensions, and engraving angle
- Area between cells
- Printing problems and image quality
- Cleaning and maintenance
05.- Printing plates
- Photopolymer plates
- Liquid photopolymer
- Solid photopolymer
- Digital plates
- Plate caliper and hardness
- Other specifications
- Machine problems, cleaning, and storage
06.- Ink regulation systems
- Ink regulation systems
- Rubber roll to anilox systems
- Reverse doctor blade systems
- Chambered doctor blade systems
- Advantages and disadvantages of chambered doctor blade systems
07.- Common printing problems
- Printing problems caused by machine adjustments and parameters
- Overprinting, trapping, bleed, and filling-in
- Most common problems and solutions
- Steps to improve printing performance in the plant
08.- Prepress and repro printing
- Process color printing
- Dot gain
- Types of printing
- Screens and gradients
- Machine test: objectives and execution
- Machine test and measurement of printing characteristics
- Machine test and conclusions
09.- High-quality printing
- Substrate
- Types of flutes
- Anilox rolls
- Inks
- Ink control
- Printing plates
- Overprint varnishes
- High-quality printing machines
10.- Digital printing
- Digital printing on corrugated board
- Inkjet printheads
- Digital printing machine
12.- Rotary die cutting
- Rotary die cutting: concepts and parameters to control
- Influence of papers on die cutting
- Prefeeder and feeder
- Printing units
- Die cutting section
- Vibrator, scrap removal, and delivery
- Order and cleanliness on the machine
- Checks before production
- Checks during production
- Palletizing and warehouses
- Die design
- Use of the die in the plant
- Cutting rules
- Creasing rules
- Rubbers in the die
- Polyurethanes
- Preventive maintenance of the die
- Most frequent problems in rotary die cutting
- Box dimensional variations: piggyback effect
13.- Casemaker, regular slotted container, and FEFCO 0201
- Flap box and casemaker concepts
- Prefeeder and feeder
- Flexographic printing units
- Slotter: creasing shafts
- Slotter: knife shafts
- Folder gluer
- Counter, bundle ejector, and palletizing
- Order and cleanliness
- Checks before manufacturing
- Checks during production
- Palletizing and warehouse
- EMBA casemaker video
- High-speed Martin casemaker video
14.- Flat die cutting
- Die cutting concepts, types, and control parameters
- Influence of papers on flat die cutting
- Influence of corrugated board on die cutting
- Flat die cutter evolution
- Feeder, gripper bars, and transport chains
- Die cutting section
- Scrap removal and bundle former
- Die design
- Proper use of the die in the plant
- Make-ready sheet
- Die wood
- Cutting rules
- Cutting knife specifications
- Creasing rules
- Creasing rule specifications
- Rubbers in the die
- Rubber specifications
- Nicks
- Scrap removal specifications
- Cutting plate and working pressure
- Preventive maintenance of the die
- Order, cleanliness, and process control before production
- Process control during production
15.- Paper, corrugated board, and box tests
- The corrugated box
- Compression tests on paper
- Other paper tests
- Corrugated board tests
- Corrugated board ECT test
- Box compression test: BCT
- Differences between static and dynamic compression
- Compression losses during the production process
- Box functions
16.- Converting waste
- Waste in converting
- Waste in feeding, printing, and die cutting sections
- Waste in die cutting caused by process deficiencies
17.- Production units
- Definition, implementation, and support tools
18.- Maintenance
- Maintenance in a corrugated board plant
Meet the Course Instructors
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