AZAD OFFSET PRINTERS(P)LTD

ACKNOWLEDGEMENT

At the very outmost, we would like to extend our deep gratitude to Mr. LALIT
AZAD, Managing Director, AZAD OFFSET PRINTERS for providing me this
opportunity to undergo industrial training at such an esteemed organization.

This is not mere formality, but means to express our heartfelt gratitude.
Throughout my endeavor to make this industrial training a success, many people
have always provided me copious support. our knowledge from the bottom of our
heart those who were solicitous and benevolent enough to guide me through out
the period.

First and foremost we would like to thank our college for providing such an
experience, which has really exposed us to the industrial environment. This
training has taught us a lot of lessons such as to be self reliant on performing the
tasks assigned to you, to be concentrated on the work while doing which otherwise
causes many losses both to ourselves and others. Hence as trainees, this training
has enhanced my scope of thinking and has made mature enough to appreciate
things that are merely on papers during my academic curriculum. we would like to
thank my college training and placement officer MR. SANJEEV MATHUR
(TPO of Department of Printing Technology) for their guidance and timely help.
And last but not the least, we express our sincere thanks to all the technical Staff
members of AZAD OFFSET PRINTERS and of the department of printing
technology, Hisar from whom we received full cooperation.

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COMPANY PROFILE........

AZAD OFFSET PRINTERS (P) LTD.

144-Press Site, Industrial Area, Phase-1, Colony No. 4
Chandigarh - 160002, India
Phone : 91-172-4611489/2652349/2651316
Fax : 91-172-2654411

Brief overview
Product innovation is the key to success in a highly competitive business
environment and is a key element in preventing the stagnation of any organization.
Innovation is what Azad Offset Printers (P) Ltd. practice since the year 1994.
Company is recognized as a reputed manufacturer of a varied range of products,
which includes Multi-colour Offset Printing, Computer Stationery, Computer
Invoices, Greeting Cards, Wedding Cards, Paper Bags, Books, Souvenirs,
etc. All our products find wide application in our daily lives, be it personal or
professional.

Product Range
Azad Offset Printers (P) Ltd. is acknowledged as an eminent manufacturer of a
range of stationery products, which includes:

 Multi-Colour Offset Printing of the highest quality

 Computer Stationery
 Computer Invoices, Stationery Pre-printed Invoices, Letter Heads in
plain, EZR, multi size, and multi-color varieties
 Computer Paper
 Greeting Cards
 Wedding Cards
 Visiting Cards, Letter Heads, Bill Books

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 Paper Bags
 Books, Brochures, Calendars, Posters, Wrappers, Table Mats
 Labels, Stickers
 Souvenirs, Catalogues, Diaries
 Pamphlets, Danglers, Leaflets, Handouts.

Clients
Some of the major names gracing company clientele are the likes of BSNL, LIC,
etc.

Quality Assurance

Quality is of prime concern at Azad Offset Printers (P) Ltd., and is always upheld
under all circumstances and conditions. To make sure prestigious clients are
provided with only premium products, strictly adhere to the international quality
norms and set industry standards.
A team of quality inspectors keeps a strict vigil on the production process, thereby
ensuring an error free produce. The final products are checked for any loopholes
and only the flawless goods are dispatched for sale in the market.

Strengths
Azad Offset Printers (P) Ltd. has a robust infrastructure replete with all the state-
of-the-art machines, which are of the latest technology. These machines give a
competitive edge to our company as they are high on production and low on the
production and the maintenance cost. They are upgraded from time to time to keep
them at par with the latest technological strength.

Workforce
Dedicated, extremely artistic and creative people constitute our workforce. They
are thoroughly committed to the company and think out of the box to come up with
innovative solutions for the clients. Regular training imparted to them, gives them
an overview of the current market scenario and helps them perform at par with the
market competition.

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Awards

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What is inside.......

1. Pre Press Section

Plate Making Section

Reuse of plates

2. Press Section

Introduction to offset printing

Various printing machines

Chemicals used in press sections

3. Post Press Section

4. Others

Machine manufacturing

Screen printing

Computer stationary

Computer paper

Computer STY plant

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1.Pre Press Section

Offset printing is widely used printing technique where the inked image is
transferred (or offset) from a plate to a rubber blanket, then to the printing surface.
Principle: - An offset image is produced by transferring the image from an inked
printing plate onto a rubber blanket, then transferring the image from the blanket to
the paper. Transferring the image from a blanket to the paper rather than
transferring directly from plate to paper has several advantages. Paper has an
abrasive on printing plates

Sheet fed offset press operation: - The offset presses are composed of four basic
units: Feeder, Registration, Printing and Delivery.

Feeder Unit:- One method of classifying presses is lay the form of the material
sent through the feeder system. The main work of feeder unit is to feed the
substrate. The feeder unit for a sheet fed offset press must separate the top sheet of
paper from the infeed pile, pick it up & deliver it to the registration unit. A detailed
study of completed automatic feeding unit may be divided into the following
groups:-

(a) Pile board (b) Sheet Separation

(c) Sheet Lifting &Forwarding (d) Sheet Controls

(e) Sheet Resister

(a) Pile Board : The Printing sheets are placed on its surface after proper
jogging. The different part of sheet board as under:

a) Front Stopper b) Side Stopper

c) Back Stopper d) Side Adjusting Screw

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(b) Sheet Separation :

The main part of this automatic feeder is its Air sucking system. Suckers separate
and lift only one sheet from top of the paper pile.

Main Parts:1) Air Blower 2) Brushes 3) Blower Foot

(c) Sheet lifting & forwarding:The lifting &forwarding of the separated sheet
from the pile of the paper is done by two sets of feeding unit. Two rubber piles
coming from the compression unit are joined with the lifting &forwarding suckers.

1. Lifting Suckers

2. Forwarding Sucker

(d) Sheet controls: From guide wheel up to front lays there are several parts to
transport the sheet all these parts are called sheet controls and described as under:
1) Guide Wheel 2) Bosses

3) Endless Tape 4) Sheet Detectors

(e) Sheet register:The term sheet register normally denotes the position of the
printed image on the sheet. Here, only sheet of paper is prepared to get correct
register in printing. Now a day’s three point lays system is used. Two of the points
are in front and one is at the side. Front Lays: These are two or four in numbers,
fitted at the edge in balancing position of the larger side of the sheet.Side Lays:
The side edge is registered by the side lay. There are only two in machine. They
are on operator & gear side.

Registration unit:- Registration is process of controlling & directing the sheet as

it enters the Printing unit. The goal of registration is to ensure absolute consistency
of image position on every sheet printed. When one color is to be printed over
another on a single sheet, the image will not fit unless registration of all sheets is
held throughout the press run. Registration is the alignment of the printing plates as
they apply their respective color portion of the image that is being printed. If the
plates do not line up perfectly the image will appear out of focus. In the printing
the registration marks that are present on each plate are positioned correctly with

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the help of front lays & side lays. Side lays pushed or pulled the paper horizontally
& placed in proper position. The front lays move out of the way & the sheet will
move in the printing unit, after a regular interval of time each sheet will enter in the
printing unit. The front lays stops the paper for a very-very little time so that a
single sheet enters in the printing unit at a time. If the registration is not correct
then it will be corrected by adjusting the side lays. With the help of side lays we
can adjust the registration upto 1.5mm. If the misregistration is more than 1.5mm
than it will be corrected by the adjustment of plate. By tightening the plate we can
adjust the registration upto 4mm. By doing this correct the registration.

Printing unit: - The printing unit places a water solution & ink on the plate,
transfers the image on the paper & delivers the paper to the delivery unit. The
printing unit must be adjusted so that the proper amount of ink & water solution is
deposited on the printing plate and so that the image is transferred evenly,
accurately and consistently to the printing paper. Every offset printing unit is made
up of three parts. The cylinder system

The dampening system

The inking system

Cylinder system configuration: - The cylinder system for any offset lithographic
press has three functional groups, a plate cylinder, a blanket cylinder & an
impression cylinder. The function of plate cylinder is to hold the plate & revolve it
into contact with the blanket cylinder during the printing process. The plate
cylinder has some form of stamping system that holds the plate squarely & firmly
in place. Ink & water ‘form roller’ contact the plate while it is attached to the plate
cylinder, thereby causing the image areas to be inked. The plate image is
transferred to the blanket cylinder, & the image is reversed. The press sheet is then
passed between the blanket & impression cylinder, where the image is offset back
to right reading. The impression cylinder applies the necessary pressure against the
blanket & paper to transfer the image from the blanket to the paper.

Inking unit :- The goal of inking unit is to place a uniform layer of ink
across every dimension of printing plate

a) Inking Unit Configuration:-

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b) Ink fountain & fountain rollers

c) Ink distributor rollers

d) Ink form rollers

The ink fountain stores a quantity of ink in a reservoir & feeds small quantities of
ink to the rest of inking system from the fountain roller. The ink distributor rollers
receive ink & work it into a semi-liquid state that is uniformly delivered to the ink
from rollers. A thin layer of ink is then transferred to the image portion of the plate
by the ink form roller.

Dampening unit: - The most plates function on the principle of water & ink
receptive areas. In order for ink to adhere only to the image areas on the plate, a
layer of moisture must be placed over the non-image areas before the plate is
inked. The dampening system accomplishes this by moistening the plate
consistently throughout the press run. Like inking systems, the dampening system
also contain some form of fountain, a fountain roller, a doctor roller, distributor
rollers & one or more form rollers.

The dampening fountain roller sits in a pool of fountain solution stored in the
dampening. As the press runs, the dampening fountain roller turns, picking up
fountain solution from the fountain & holding it on its surface. A doctor roller jogs
back & forth touching the fountain roller, where it picks up fountain solution then
touching a dampening distributor roller. The distributor roller takes the fountain
solution from the doctor roller to the dampening from rollers, where it is
transferred to the plates.

Delivery Unit: - The delivery unit takes the papers from the printing unit & places
are on an outfeed table. As the sheet leaves the printing unit, it is dropped into a
delivery pile. As the sheet leaves the printing unit, a set of mechanical fingers
(grippers) grab the leading edges of the sheet & pulls is out of the printing system.
The gripper bar is attached to a continuous chain that moves the printed sheet to a
paper pile releases it & moves the gripper back & receive another sheet. The chain
moves at a same rate and in synchronization with the feeder, registration &
printing units.
This is the section where image carriers for printing are prepared using different
matterials, chemicals and equipments.
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Plate Making Department:-

Technova and local manufectured plates are used in offset printers. Films are
used for making plates. Impostion of pages are done mannualy on light table.
Following three points complete the plate making dept.:-

Plate specifications

Plate making

Reuse of plates

Specifications about Plate:-

Name of the company Technova

Type of Plate UV-CTP(+ve plate)

Length*Width*Thickness 37*30.5 inch(largest)

21.5*27.5 inch( full size)

Quantity 50N

Storage Content are light sensitive

Stored in cool dry place

Manufacture Agfa-Gevaert N.V.

Other local manufured plates specifications:-

sizes of plates 740*770 mm

525*650mm

550*650mm

641*527mm

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Plate making:- Following steps are involved in plate making:-

Computer to film:-CTF can also be termed as image setter. These are the
electronic machine which generate photographic films either positive or negative
as our desire. The machine are enclosed in an air conditioned room. These machine
are the most commonly used in printing industry but now there is an advent of CTP
which is of higher cost but has higher efficacy.

Working:-

The data to be printed is send to the CTF computer from pre press dept. Then
this electronic data is converted into digitized form. Then a laser beam start acting
as moves over the film is been made. In this we directly get the positive to be used
to expose the plate.

Impostion:- impostion are done mannually by using different impostion charts. the
different films are pasted on plate for exposure.

Exposing:- A special and manually made exposing unit expose the plates. Five
star film for screen printing exposure time kept 190 second.

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Developing/washing/gumming:- All the three operations are perfomed in a sing

unit. After exposing a plate it is shifted to a conveyor which transfer it to next
function. After exposing this conveyor belts passes from a tub of developing
solution. This developing solution tub is connected to a series of pipes. These pipes
regularly keep supplying a fresh amount of developing solution in developing tub.
In developing units all the unexposed coating from the plate get removed away
leaving the exposed area which is required for printing

After developing some amount of developer remain stick with the plate. To remove
this extra developer room the plate is further passed from tub of fresh water. This
water tub is also provided with a supply of fresh water and removal of used water.

After washing gumming is done. It is done to make plate more durable and
protected from oxidation.

Punching:- a punching machine is used for puching the plates for different
purposes like to mount the plate on printing machine.

Chemicals used in pre-press:-

nova dense

laser image density booster solution

delete solution

Reuse of plate:- The reuse of plate are done in two ways:-

1. The light sensitive emulsion is used on used plated after neccessary operations
performed on plate like cleaning.

2. The local plate making companies also provide plates with both side coating.
these plates can be used two times.The purpose of these plates is to take print in
small number say 5000 or other short run job

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2.Press section

All the singe colour work is done on the single colour manual machine and
all other multicolour work on automatic multicolour offset sheet fed machine.
Different offset machine present in press are:

Print auto PTP 7000

Akiyama HA 228T

Dominant 755

Rotary web offset with inline operation (perforation and punching)

Screen printing machine

HMT and Pratika and ronald

AUTOPRINT PTP 7000:-

Model Autoprint PTP 7000s (Single Colour)

Paper length 178 to 330 mm (7" to 13")
Paper Width 102 x 482 mm (4" to 19")
Printing Area (Maximum) 482 x 320 mm
Paper Thickness 40 to 200gsm
Print Speed 3000 to 7000 Forms / Hour
Plate Size 380 x 500 mm

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Blanket Size 400 x 500 mm

Feeding System Tractor Feed
Delivery System Paddle Delivery
11 Inking Rollers including 3 Oscillators and 2 Form
Inking Unit
Rollers
4 Dampening Rollers including 1 Oscillator and 1
Dampening Unit
Form Roller
Vertical Image Adjustment ± 30 mm
Vertical Paper Micro 0.1 mm (Minimum)
Adjustment 50 mm (Maximum)
Lateral Paper Micro
± 6 mm
Adjustment
Power Source 220 V, 7.5 Amps, Single Phase 50 Hz
0.75 Kw (1 HP) AC 3 Phase
Main Motor
(Connectable to single phase)
Feed Motor 0.4 Kw (400 Watts)

auto print ptp 7000

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Dominant 755 P(5 color):-

Sheetfed Press
Manufacturer: Adast
Type: Sheetfed Press
Nr. of Colors: 5
Maximum imagearea [mm]: 475x650
Maximum sheetsize [mm]: 485x660
Speed (sheets per hour): 10000
Web Width [mm]: 1340

Unitech rotary web offset:- This is a narrow web printing machine. One unit can
operate at a time, the two other unit may remain idle without cylinder rotation. The

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inline operation such as perforting and puching can be done along with printing.
The speed of this machine is 20000 Iph+.

Dominant 725(2 color):- Adast Dominant offset printing machines are widely
used & appreciated in printing industry for their attributes such as low maintenance
cost, high durability & excellent performance.

Specifications:

 Two Color
 Size 19" X 26”
 Standard dampening
 Powder sprayer
 Low pile delivery

Akiyama 4 color:- High demand for its high speed performance and low
maintenance. The machine has Akiyama's patented cylinder configuration, which
makes sure that each print has high quality. Further, the machine is provided with a
smooth sheet-transfer system that helps in using various types of substrates, which
range from thin paper to cardboard

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Chemicals used in press room:- Following chemicals are used in press room:

Plate cleaner GP – Technova

Blanket AID

United ink speedest PLUS

Fount solution

Tech reducer – united

Nova delete solution

Blanket savor

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3.Post Press Section

Post press operation are an important and integral part of job. Proper finishing to
a well printed job is what differentiate a good job and a great job. Spectrum’s
efficient post printing machinery take care of entire set of activities that one has to
undertake once the job is printed. Different post press operatioins used in the work
flow are:

1. Binding :- It is used for binding heavy books. It is an automatic machine. In

this, Firstly sections are made and then all sections are pasted to form a book.

2. Stitching :- Two saddle stiching machines were available for stitching. both
machines can side stiching as well as center stitching.

speed:-100 books/hour

3. Cutting :- Two single knife cutting

semiautometic machines were used for

the purpose of cutting. the feeding is

done by hands and all other operatioins

like setting margins etc were performed

by setting on display . a special setting made can be stored as program for future
cutting.

4. Lamination :- The Machine is Ideal for Double Side Thermal Lamination. The
lamination machine Laminate

Vinyl

Non Tearable
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Non Woven

Duplex

Art Card

Art Board

other Papers Related to Photo Album and Printing Industry

This machine can Laminate 80 GSM to 350 GSM Art

5. Folding :- To machines for folding purpose are used in press. semiautometic

machine is usually used for short run jobs. the fully autometic folding machines
used occasionaly for long run jobs. it can fold 5000 prints per hour.

6. Gathering:- Gathering is done totally by hands.

7. Numbering:- Numbering is done in two ways. the seprate numbering device is

used for small run jobs like prospectus of collages and bill and for long run jobs
like goveronmental policy forms were numbered by inline operation on rotary
web offset printing machine.

8. Trimming:- Three knife trimmer is used for book trimming.

9. UV coating machine:- It is done one the sheets to protect the image. Water
coating is also done by this machine on metallise sheet before UV printing. UV
and IR dryers are used. For drying UV coating UV dryer are used. IR dryers are
used for drying water based coating. Temperature of dryer is 50-70 degree c.

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4.Others

Screen printing:-The screen printing is used for invation cards, marksheets etc.

Two machines are used in screen printing:-

screen mannual

uv curing

Ink used:- micro inks ,vehicle of ink:- nitro

speed:- 500 copy per hour

Computer Stationary:- Supply Blank Computer Stationery that is required by

many establishments and even in households. Blank Computer Stationery is made
using the finest quality paper that makes printing very easy and cost-effective. The
Blank Computer Stationery provide comes with sprocket holes on both sides and
runs smoothly on all types of Dot Matrix or Line Printers.

The following stationery work is done by press:-

 Computer Invoices,
 Stationery Pre-printed Invoices
 Letter Heads in plain,
 EZR

Computer Printer Paper:- These products are especially made to suit both
personal and business requirements. Fine grade raw material to produce these
products so as to ensure zero defects in the finished range. These stationeries are
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widely appreciated for their durability, efficiency and performance. Further, we

also provide customized printings on the products.

Contineous computer paper:- These papers do not break and thus provide a
hassle free printing. These are ideal for high speed printing and large volume runs
in dot matrix printers.

Computer STY plant:- Azad offset printers also offer computer STY plant. A
team of skilled engineers that enable the company to fabricate computer STY
plant. Manufecutred using quality components and requisite material, these plants
are recknoned for their sturdy construction, compact design, high performance and
low maintenance. Further , the company can design these plants as per the
requirements of the clients.

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Machine manufacturing:- The company also indulged into machine

manufacturing.
The machines are manufactured according to latest standards keeping the needs of
customer in mind. The company also provide service after sale for their machines.
A machine manufacturing dept. is specially made for modifying older printing
machines which has been almost obslete from market.
Company is also engaged in supplying of various types of labeling machine.

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