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Following Uflex from Kentucky to Dusseldorf

01 July 2016

Who doesn’t know flexible packaging giant Uflex? What is more interesting, however, is how the Noida-headquartered company successfully integrates the different aspects of packaging to offer a complete solution. Thus, the company manufactures packaging films, the base material for packaging, and then, to fill the package with actual products, the company manufactures converting, filling and sealing machines.

Recently, PrintWeek India had an opportunity to take a close look at Uflex’s film manufacturing unit at Kentucky, US. We also visited the company stall at Drupa 2016, where it showcased technology and equipment for print and packaging.

In this picture gallery, we follow the homegrown company in its overseas exploits, from Kentucky to Dusseldorf.

  • A single winder’s capacity is 72,000 metres. It depends on the outer diametre of the roll. In weight, it can be a jumbo of 10,000 kg
  • The core team of Flex Films (USA), from left, Praveen Murlidharan, responsible for IT; RatneshwarJha, responsible for accounts and finance; Wayne Morris, chief financial officer; KK Sharma responsible for production and Deepak Chopra, who take cares of sales and marketing
  • A single winder’s capacity is 72,000 metres. It depends on the outer diametre of the roll. In weight, it can be a jumbo of 10,000 kg
  • Uflex Elastomer flexo printing plates and sleeves showcased at Drupa 2016
  • Thickness of the films produced at the US plant ranges from eight to 50 microns
  • The Electronic Line Shaft (ELS)-based rotogravure printing machine Ultima on display at Drupa 2016
  • With a production capacity of 30,000 MT per annum, the plant is supplemented by a plasma-enhanced high-barrier vacuum metalliser that can produce around 11,000 MT of metallised film annually
  • More than 10-metre-long heating chamber stretch the film more than eight metres width. These heating chambers run electric heaters
  • More than 10-metre-long heating chamber stretch the film more than eight metres width. These heating chambers run electric heaters
  • More than 10-metre-long heating chamber stretch the film more than eight metres width. These heating chambers run electric heaters
  • Films on jumbo cannot be used directly because of its big size (more than eight meters). Slitters cut films into sizes demand by the customers
  • The softening temperature of the chipsis 69 degrees Celsius and the melting temperature is 240-250 degree Celsius
  • The warehouse of the US plant
  • The US plant houses an 8.7 metre BOPET film line that runs at 500 metres per minute
  • Here is the first time when you can see the film in physical form. This is the base form of film and it will be stretched more than three times through heating process. Heat is generated by electric heaters
  • Uflex solvent-less laminator - standard S machine
  • At the US plant, workers come from different backgrounds, geographies, ethnicity
  • The quantity depends on diameter of the rolls. A jumbo roll takes three hours to be fully loaded
  • J Kampf slitting machines provide films on customers’ need
  • Flex Films (USA) manufacturers films on demand and follows a zero inventory model
  • White chips are made of recycled material will be used for film manufacturing again with a mix of virgin white chips
  • Chilling system with cold water maintains temperature of around 12 degrees Celsius on the surface of the roll
  • Flex Films follow a strict and regular chart of maintenance which help the company to produce films flawless
  • The US plant houses an 8.7 metre BOPET film line that runs at 500 metres per minute

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