The production process

The entire production process at Packaging Plast is based on the use of state of the art technology combined with extraordinarily high quality artisan techniques carried out by skilled, competent personnel. Each article is made to measure, in a production process in which every single step is monitored in detail. We can, however, also cater for requests for serial production.

Design

The design process

To respond in full to the needs of every individual client, Packaging Plast provides a dedicated technical support service, with consultants offering advice in the definition of the product, in consideration of the client’s specific requirements, and technicians taking accurate on-site measurements.

As Packaging Plast uses a custom production process, each doctor blade chamber is designed from scratch and fabricated for the specific intended application: from printing paperboard and narrow-web labels to printing tissue and wide-web.

The design process is the first step in the procedure, defining the mould which will then be laminated with our proprietary methods.

In this stage, the profile is defined with 3D design and structural calculation software to create the 3D model of the product.

PREPARATION 

Preparing the skins and mould for lamination

Actual fabrication begins with the preparation, cleaning and cutting to shape of the carbon fibre skins, and stabilising the mould which will be used to shape the profile in composite material.

After these preparations, the layers of carbon fibre are laid out in the mould; precise control over the direction in which the fibres are oriented is crucial in this stage, to ensure that the profile meets the requisites for stiffness.

CURING AND CNC 

Curing and CNC machining 

The mould containing the doctor blade chamber is placed in an autoclave for final curing, during which the bonding resin of the composite material polymerises.

The curing process consists of three stages: an initial cycle during which the doctor blade chamber is heated gradually under vacuum, a pressurisation cycle and, lastly, a controlled pressure release and stabilisation cycle.

The company has its own computer numerical control work centre operated by specialised technicians
This 5-axis work centre minimises machine set-up times and machining times, and produces a finished profile machined to an extremely high degree of precision.

CAD-CAM software is used to generate the machining coordinates for the work centre. The end result of the machining process is a doctor blade chamber structure with the ink passage holes and channels already incorporated in the structure itself.

ASSEMBLY

Assembly

The machining process is followed by assembly, during which all the components of the doctor blade chamber are installed together in the correct positions. Automotive grade press-fit bushes are used as a guarantee of durability of all the threads in the structure of the doctor blade chamber.

All the parts assembled in this process are manufactured in-house with latest generation materials, allowing for continuous innovation and meaning that any spares necessary are available immediately from our warehouse.

The assembly, finishing and quality control processes are carried out with minute attention to detail by highly qualified personnel.