Made in India: Pharmaceutical leaflet folding machines from Pratham Technologies

Pratham’s pharmaceutical leaflet folding machine (inserts and outserts), as the name suggests, folds leaflets into precise formats for medicines packing. “It inspects the print on the sheet by vision inspection, folds the leaflets through a leaflet folding machine, and in multiple steps automatically, then collects them for packing," Varad Deshpande of Pratham Technologies says.

According to Deshpande, "The pharmaceutical leaflet folding machine (inserts and outserts folder) uses advanced folding mechanisms, including knife and buckle folding suited for delicate leaflets. It is equipped with servo motors for precise control of fold parameters. It incorporates automated feeding and stacking for speed and accuracy."

He adds that the structure comprises a feeding unit, a folding unit, and a stacking section. The modular design allows easy maintenance and customisation. It utilises sensors for quality control and jam detection for smooth handling and safety during handling/operating. The pharmaceutical leaflet folder was first launched in 1995-96.

How packaging boosts pharma
Pratham’s machines are designed for the pharmaceutical, printing and packaging industry, focusing on print-finishing, robotic and automation and digital print. "We especially target printers and pharmaceutical packaging companies, who need to fold leaflets, inspection solutions and packaging components accurately and efficiently, while also wanting automation and quality control to improve their production processes," Deshpande says.

He adds that the company’s machines are suitable for India’s price-sensitive market because they increase productivity and reduce labour costs. By automating folding, inspection & collection processes, they help businesses operate faster and with fewer errors.

"In terms of cost-effectiveness, these machines reduce manual labour expenses, minimises material wastage and increase throughput with faster production cycles," Deshpande says. He adds, "In terms of on-time delivery, automated processes ensure consistent quality and speed, less downtime due to fewer errors or jams. Plus, faster turnaround helps meet tight schedules."

The company's robotic automation combines robotic arms with programmable logic controllers (PLCs) for tasks like loading, unloading, handling the product efficiently. It features inspection systems, a sampling box for precise alignment and quality inspection, and enables seamless integration with existing production lines for automation.

Pratham's commercial folding machines use mechanical and electronic components for high-speed, accurate folding of various materials and complex folding patterns. They are capable of multiple fold types —parallel, Z, or custom folds — adjusted via touch screen interfaces.

Its print inspection systems use high-resolution cameras and image processing software to detect print presence absence, pharma code, barcode, and pattern match. Its automated rejection and correction features enhance quality control.

How Pratham has built pharma fortunes
The pharmaceutical leaflet folding machine is deployed by pharmaceutical companies, large printing houses, and packaging firms globally, especially in regions with strong pharmaceutical and printing industries such as Europe, North America, Asia, Middle East, Africa, Russia, and Australia.

Pratham's key customers using the outsert folding machines include Art-O-Print; Art-In-Art; AMR Print and Pack; Light Publications; Pravesha Industries; Parksons Packaging; Kumar Printers; Print Point Pharma; and Arunodaya Print Pack, among others.

Deshpande says while choosing such a product customers usually look for reliability, efficiency and cost-effectiveness. "The machine should work smoothly without frequent breakdowns,” he says. “It should increase speed and reduce manual work. It should offer good value for money with low operating costs. It should be simple to operate and maintain. It should offer consistent, high-quality output." Deshpande adds, "The after-sales support should have strong service and parts availability. And most importantly, the machine should have the ability to handle different sizes and types of products."

A new era for pharma folding
Deshpande says the machine offers quick and reliable folding and inspection. Also, it reduces manual work and human error, and ensures uniform folding and printing checks. It has user-friendly controls and simple maintenance. It works with different sizes and types of materials. The machine offers reliable performance in busy production environments and minimises waste while improving productivity.

The components of the machine include round pile feeder; first fold station starts from eight plates to 24 plates; right-angle folding unit; knife and pressing unit; creasing pre-setter; glue detection and SuperPrint and inspect; and super tray packer (STP).

Deshpande adds that the company offers on-site installation and training, virtual sessions or online support, and training manuals and quick-start guides.

With the RPF 53 (outsert folding machine), the company plans to expand its footprint in Europe and North America. The company also has plans to launch new projects and set up new service centres globally. In 2025-26, Pratham is targeting 25% YoY growth in the pharma automation segment.

"The machine significantly boosts productivity by increasing folding speed, reducing manual effort, and minimising errors. It allows for continuous, high-volume operation, helping businesses meet tight deadlines and improve overall throughput efficiently," Deshpande signs off.