Description
Course Details
- Online Training Hours: 50 hours
- Live online classes with the instructor
- Duration: 3 months
- Start date:
- Eligible for FUNDAE funding (Spain)
Objectives
- Identify and classify the main sources of waste generated on the corrugator.
- Identify the main sources of waste in each converting machine.
- Analyze the specific causes of waste in flexographic printers, FFGs, and rotary die cutters, including front stops, guides, anilox rolls, ink systems, and printing plates.
- Detect printing errors related to inks, printing plates, and machine settings that affect quality and increase product rejection.
- Evaluate critical waste-generation points in the slotter, folding, gluing, and delivery sections of the Flexo Folder Gluer.
- Understand the impact of die design and its components
(cutting knives, creasing rules, rubbers, and tie points) on rotary and flat die-cutting efficiency. - Diagnose the causes of waste in folder gluers,
from initial alignment through adhesive application and the final press section. - Provide technical criteria for defining corrective actions
to reduce waste and improve overall equipment efficiency.
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
1.- Waste in converting
- Causes of converting waste
- Waste control procedures
2.- Waste in FFG and rotary die cutter feeders and printers
- Feeding system waste
- Front stops and guides
- Flexographic printing units
- Waste caused by anilox rolls
- Ink regulation systems
3.- Waste caused by printing, inks, plates, and machine problems
- Waste generated during printing
- Ink-related waste
- Plate-related waste
- Machine parameter deviations
- Printing problems
4.- Waste in the Flexo Folder Gluer: slotter, folding, and delivery
- Creasing defects
- Knife and cutting defects
- Slotting and die cutting knives
- Folding section
- Gluing system
- Bundle counter ejector
5.- Waste in rotary die cutting
- Die-holder cylinders
- Polyurethane cylinders
- Vibrator and stacker
- Dimensional variations and piggy-back effect
6.- Waste in flat die cutting
- Feeder
- Gripper bars
- Die cutting body
- Scrap removal and bundle former
- Die design: cutting knives
- Die design: creases
- Die design: rubbers
- Tie points
- Scrap ejection
- Top Matrix
7.- Waste in folder gluers
- Feeder
- Aligner and automatic bottom
- Folding, delivery, and press modules
- Adhesives and gluing systems
