Page1

Why Compromise?On Quality & ProfitsBuy, Sale, the Best, Earn the Max.

This is a general comment / remark , today , All the Industries are facing this issue. Especially theAdhesive Tape Industry is facing a very stiff competition , within local manufacturers , as well asChinese Manufacturers . So the question is how to tackle this ?

YesThe answer is we have to be cost effective.But is it sufficient to be just cost effective ?NOWe have to be cost effective , with no compromise in quality , quantity .YesWe can face stiff competition by offering quality product and also in huge quantity

NowHow to be cost effective ?We will try and see the ways and means to be cost effective.This is big challengeBut we can accept this and achieve it

We all knowThat for the manufacture of any kind of Adhesive tapeWe need basicallyThe Necessary raw materialsThe machinery or equipment , for coating, slitting , packingThe testing equipmentEnergy , like Electricity , FuelManpower to operate the machinesA Industrial Shed , shop floor to install the machines

Knowing this we can understand that the cost of the Adhesive tape product can be basically divided into4 different headsRaw Material costThe Packaging Material costThe Manufacturing CostThe last but the most important one is the Profit

So now the question is

Dec,152017Contact : psatechno@gmail.comWhat’s app /Cell : 00 91 9850242282

Page2How to be cost effective inRaw Material cost , that is invariably contributes to approx. 50-55 % of the total costThe Packaging Material cost, which depends on the type of packing required . For individual / singleunit pack the cost can be bit high , but for group pack the cost is quite low. On an average let’s , saypacking cost is approx. 5-10%The Manufacturing Cost , this is the cost which can be described also as manufacturing overheads . Thisincludes the cost of labor, Fuel, Electricity , Factory rent or interest on Bank loan for factory shedconstruction. We can say that the cost will be approximately 20-25 %Rejection by Quality Control Dept , could be approx. 3 %The last but the most important one is the Profit . This may depend on the type of the end product. Formass production item it could be approx. 10 -15% , and for specialized products it could be from 20-25%

How the cost breakup will beRaw Material cost , let us assume approx. 50-55 % .The Packaging Material cost, let us assume approx 5 - 10%The Manufacturing Cost , let us assume 10-15 %Rejection ,could be approx. 2-3 %The last but the most important one is the Profit . Let us assume 20-25 %

Here we all have to agree on , one basic principal of operating a Businessthat produces , Quality Product , aiming at bareminimum process wastage and , zero % rejection ( Ideally )We can achieve this target or goal, provided we buy ,the Best Quality , Raw Material, Packaging Material, Manpower, andFuel

Now , it's our policy to , Produce Best Quality Product and Earn a min of12.5 % Profit , and how , we can aim at 25 % Profit ?

Page3So Which are the components of expense Heads , where we can , cut ourCoat ? , with No compromise on quality of our end product?

Hence we will realize that , there is hardly any chance of cost cutting ,under the heads of Raw material cost , Packaging Material cost .The Predominant area where we can save or cut our cost isManufacturing Overheads , and reduce the process Rejection.

Hence we have ultimately identified the area’s where we have a sizablesaving , with no compromise on qualityAnd this area , which will be responsible for earning more profits isCONTROLLING OR REDUCINGMANUFACTURING OVER HEADS & REJECTION

Page4

IN OTHER WORDS , WE SHOULD NEVER COMPROMISE ON THE QUALITY OF RAWMATERIALS , PACKAGING MATERIALS. WE MUST BUY THE BEST QUALITY RAWMATERIALS , ( SINCE IT CONTRIBUTES TO APPROX. 52 % OF THE TOTAL COST.AT THE SAME TIME , WE SHOULD LOOK INTO , REDUCING MANUFACTURINGOVERHEADS AND REJECTIONS.

Page5Labor / Manpower Cost will be almost on similar scales , from Unit to Unit. This is one of the majorcost to the company. The labor Cost can be reduced only by increasing the production speed, byincreasing the efficiency of the coating , slitting and other machines.Hence the Management has to take innovative , steps to adopt , latest technology , upgrade , modify orreplace older machines with the latest models.The Labor cost can be reduced byGoing in for wider width machine, say from 1000 mm to 1250 mm or even 1500 mmGoing in for higher speed machines , say from 40-50 mtr. per minute to say 75-100 mtr. Per minuteGoing in for multi station coating , or adopt new technology and carry out , two or three coatings in asingle pass, for e.g., Priming , backside release coating and Adhesive coating , all in one passThese major’s will help a lot in reducing the labor cost withoutcompromising on quality or skills of labor.

Electricity Cost will also be on similar scales , from Unit to Unit. This is one of the major cost to thecompany. The Electricity Cost can be reduced only by increasing the production speed, by increasingthe efficiency of the coating , slitting and other machines.The Electricity cost can be reduced byGoing in for wider width machine, say from 1000 mm to 1250 mm or even 1500 mmGoing in for higher speed machines , say from 40-50 mtr. per minute to say 75-100 mtr. Per minuteGoing in for multi station coating , or adopt new technology and carry out , two or three coatings in asingle pass, for e.g., Priming , backside release coating and Adhesive coating , all in one passBy adopting solar energy based Innovative heating systemsThese major’s will help a lot in reducing the Electricity Cost withoutcompromising on quality or skills of labor.

Fuel Cost will also be on similar scales , from Unit to Unit. This is one of the major cost to thecompany. The Fuel Cost can be reduced only by increasing the production speed, by increasing theefficiency of the coating , slitting and other machines.The Fuel cost can be reduced byGoing in for wider width machine, say from 1000 mm to 1250 mm or even 1500 mmGoing in for higher speed machines , say from 40-50 mtr. per minute to say 75-100 mtr. Per minute

Page6Going in for multi station coating , or adopt new technology and carry out , two or three coatings in asingle pass, for e.g., Priming , backside release coating and Adhesive coating , all in one passReplacing petroleum based fuel to bio mass, bio diesel etc.These major’s will help a lot in reducing the Electricity Cost withoutcompromising on quality or skills of labor.

Bank Interest will also be on similar scales , from Unit to Unit. This is one of the major cost to thecompany. The Bank Interest impact can be reduced only by increasing the production speed, byincreasing the efficiency of the coating , slitting and other machines.Hence the Management has to take innovative , steps to adopt , latest technology , upgrade , modify orreplace older machines with the latest models.The Bank Interest burden can be reduced byGoing in for wider width machine, say from 1000 mm to 1250 mm or even 1500 mmGoing in for higher speed machines , say from 40-50 mtr. per minute to say 75-100 mtr. Per minuteGoing in for multi station coating , or adopt new technology and carry out , two or three coatings in asingle pass, for e.g., Priming , backside release coating and Adhesive coating , all in one passAdopting solar energy concept.These major’s will help a lot in reducing the labor cost withoutcompromising on quality or skills of labor.

Rejection is a direct loss incurred , whether it is in house or at customers end.To some extent , Rejection , in house , that is the product being rejected by the Quality Assurance Dept ,inside the Manufacturers own premises is permissible to some extent.ButRejection at the customer’s premises is really a very serious matter and it harms the manufacturer inmany ways.1. It is loss of money2. Loss of reputation3. A big threat of losing the entire business .Rejection has to be avoided at any stage , of the Manufacturing process.These stages could beRaw Material procurementMaterial in processSemi finished ProductFinished products , etc.

Let’s see how do we avoid the Rejection , at these stages ,Raw Material procurement

The Raw Material specifications , must be carefully prepared and , than these specificationsshould be religiously followed. There has to be some scope for , slight deviation in these specifications ,at a particular stage , that will not harm the end product specification drastically.2. Material in process

The material Processing Parameters should be drawn carefully , and the same should be followedreligiously.3. Semi finished Product

Page7The Product specifications at this stage also should be drawn seriously , and the same should be

followed religiously.4. Finished products , etc.

The Finished Product specifications should be drawn seriously , and the same should befollowed religiously.

Page8

Page9

Page10

Page11

Page12

Page13

Page14

Page15

Page16

Page17

Page18

Page19

Page20

Page21

Many a times a compromise is done on the Rewind and Unwind tension control systems.A relatively old clutch and brake system is preferred in place of auto tension controlling devices.No doubt you save some Money in terms of low capital InvestmentBut the result ?You keep losing money every day in terms of wastage and rejection, and sometimes may be thereputation or loss of the customerWhy this happens ?

Why ?Because the rewind tension set at the beginning of the coating is say “ X ”As the coating progresses and the diameter at the rewind end increases , there is a increase in thetension. This affects the line speed. As a matter of fact the line speed increases , andThis results in improper drying, increase in residual solvent , unwanted wrinkles and creases , whichultimately results in higher wastage or sometimes rejections.

Types of Coatings that can be handledWater borneOr

Page22Solvent borneOrsolvent lessOrhot meltHigh viscosityOrLow viscosity

Quality the ease of change over'sProduct Change over's can contribute to the quality of final productToo many change over's can contribute to a huge loss of raw materials, time , and manpower hoursUltimately resulting intoUnwanted wastage of Raw Material, precious production time, electrical energy , fuel and moreexpensive manpower hours

Quality the machine control panel user-friendly or complicated ?

A user friendly Control panel can save a lot’s of time , and energy as well as man power hours .That’s how the wastage can be under control

Quality coat ability, the coating methods available , faulty or unsuitable coating methodsFor sake of convenience let us consider water borne and solvent borne coating that are morecommonly used.The viscosityThe solids contentThe rheological property of the coatingPlay a important role in the coating processA proper coating method is responsible for lower wastage

Quality

Page23 coat ability, the coating methods available , faulty or unsuitable coating methods

For sake of convenience let us consider water borne and solvent borne coating that are more commonlyused.The viscosityThe solids contentThe rheological property of the coatingPlay a important role in the coating processA proper coating method is responsible for lower wastage

SimilarlyComma , reverse Roll coating is meant for higher Viscosity ( 1000 to 6000 cps ) coatings orAdhesives.Generally the specialty Tapes / or tapes with release liner based on Solvent based adhesive or WaterBased Acrylic adhesive , with an average solids content of 50-52 %Are coated by this method.Now in case if someone tries to coat lower viscosity adhesives by this method than the coating will notbe even or it will result into low coat weight.The result is Wastage of adhesive coated product ( low weight of adhesive ), and Excessive drying ,resulting into another rejection.Even while attempting to coat the adhesive will tend to leak out from the check plates at the sides of thecoating roll.

Page24

Page25

Page26

Page27

Page28

Qualitymachine drying tunnel efficiencyAlso depends on lower capacity Heating Source , Hot Air Generator, or Thermo pack improper air distribution absence of exhaust system air leakage from sides too large or too small drying tunnel correct air velocity

Quality Lower Capacity Heating Source , Hot Air Generator, or Thermo pack Hot air / Thermo pack are available in various capacities like 50000 cal / 100000 cal/ 200000 cal

/ 400000 cal etc.

Page29 more the capacity more is the fuel consumption ( like diesel, LDO, furnes oil etc. ) in order to keep the fuel consumption low , generally the lower capacity Hot Air generator or

Thermo pack is chosen. This is the reason the expected coating speeds are not achieved , or the coating is done at higher speeds without efficient drying and results into adhesive transfer

and huge wastages.

QualityAbsence of exhaust system

in some of the cheaper designs of drying tunnel , the exhaust system is missing. Actually for efficientdrying the exhaust is necessary just to replace the air .The air with water of solvent vapor saturation needs to be replaced with fresh air so that more water orsolvent vapor could be absorbed.Incase if the exhaust system is missing then the air inside the drying tunnel is always saturated and nofresh vapor can take place efficiently.

Page30 QualityAbsence of exhaust system

Page31in some of the cheaper designs of drying tunnel , the exhaust system is missing. Actually for efficient

drying the exhaust is necessary just to replace the air .The air with water of solvent vapor saturation needs to be replaced with fresh air so that more water orsolvent vapor could be absorbed.Incase if the exhaust system is missing then the air inside the drying tunnel is always saturated and nofresh vapor can take place efficiently.

Page32

Any compromise or deviation in drying efficiency is going to result in unwanted wastage of heatenergy, electricity . Man power cost .This will ultimately increase the cost of manufacture , and result into lower , or sometimes NO Profitsat all

The last but the most important one is the ProfitHere we all will agree that thequality and quantitywill play a major role in controlling the cost.How ?Let us analyze the same one by one.

Another major issue with many tape Manufactures ?Give a guess ??????YesYou are right

Page33There is no testing facility.Lack ofQuality ControlAndQuality Assurance Testing

I am sure some of you might be shocked to know this , but trust me I have seen somemanufacturers , where there is no other testing equipment except a mere Thickness gauge and aGSM balance

Quality ControlQuality can be monitored and controlled while manufacturing. The Product will have good quality andthe wastage will be below 2-3 % or Rejection will be avoided.The basic tests as mentioned below can help you to produce a right product .

1. Web Thickness and GSM2. Adhesive thickness and GSM\3. The residual solvent / water under 0.2 %4. Web shrinkage under control5. Proper rewind tension ( the rewound roll is never rock hard , etc.

Quality AssuranceQuality cannot be rectified or altered after the coating or slitting process is over.Quality Testing is only possible , but the properties cannot be altered. The reworking , in many a cases isimpossible ,AndOr the same is very expensive if possible .

ConclusionTape manufactures Can you survive the cut throat Competition ?The answer is : YESYou canHow ?

Aim atminimum Wastage and Zero Defect or Rejection.Choose , Right quality Raw Materials , A correct machine Trained manpower Bare minimum Testing equipment Draw product specifications, process parameters and follow them strictly

You can reach me on,Whatsapp : 0091 9850242282Email : psatechno@gmail.com / spathavale@rediffmail.comLinkedin Profile : https://www.linkedin.com/in/shrikantathavale4adhesiveconsu