Why UV Graphic’s Ultraflex is reshaping India’s hybrid press market

When a customer in Hyderabad ran a high-value FMCG label job with ten colour changes and multiple embellishments and completed without a single registration error on a UV Graphic Ultraflex press, it was more than a technical success. It saved the customer a reprint worth thousands and strengthened confidence in Indian-built technology. “We are giving converters peace of mind,” says Abhay Datta, managing director of UV Graphic Technologies. “And we are doing it with Indian engineering.”

This, as Datta frames it, is the thesis of Ultraflex, a hybrid modular platform designed and manufactured in Noida. 

Pioneering Indian innovation
Ultraflex represents a significant departure from dependence on European, American, Chinese and Japanese platforms. Datta emphasises that 60% of the build, including machine frames, print and magnet cylinders, plate mounters, UV and LED UV and control systems, are sourced and fabricated within India. This level of localisation reduces supply chain risks and enables faster service turnaround. For converters, it translates into lower costs and fewer delays.

The machine is built on a rugged mono-frame chassis that eliminates vibration and ensures register accuracy. “Pharma jobs cannot tolerate misregistration in security features or barcodes,” says Datta. 

Datta having been a printer himself and running a successful printing unit for the past 45 years has evolved his presses around the needs of the printer and press operator. Every Ultraflex press manufactured by UV Graphic is personally run and tested by Datta. 

Datta is clear that the innovation is not about imitation. “We are not copying European designs. We are innovating for the Indian environment,” he explains. Ultraflex has been engineered to run without air conditioning, without UPS or voltage stabilisers, and to withstand power fluctuations, high humidity and continuous multi-shift operations.

Where international OEMs may have assumed stable infrastructure, UV Graphic has designed for the reality of India’s industrial clusters.

The system can be configured from two to sixteen colours, with inline converting and embellishment. Over the past year, demand has grown for tactile finishes and special effect coatings such as raised varnishes. UV Graphic responded by ensuring the press can accommodate heavy deposition screen and gravure units within the same platform. 

Another dimension of Indian innovation is the cost structure. By focusing on modularity, UV Graphic enables converters to invest incrementally rather than committing upfront to high capital expenditure. Datta notes that Ultraflex is helping reshape perception. “Earlier, people said Indian machines cannot compete with global quality. Today, our presses run jobs that meet international benchmarks.” 

Operator-centric engineering
The design philosophy of Ultraflex begins with the operator. Datta points to a recurring challenge in Indian plants: high staff turnover and limited print room supervision. To address this, the press features a job recall system that allows operators to reload settings with near-perfect accuracy. “A new operator can run the same job with 99.99% consistency,” says Datta.

For converters working three shifts, consistency is critical. Each module on the Ultraflex has diagnostic indicators and is designed for ease of servicing. Components like UV lamps, rollers and sensors can be replaced without specialised tools. “We design for people who may not have OEM engineers on call,” Datta explains. 

Space constraints are another driver of design choices. Many Indian converters operate in industrial estates with limited floor areas. Ultraflex presses are built with compact footprints, the lowest the industry has ever seen, enabling installation in environments where international suppliers may hesitate. “We design for the space you have, not the space you wish you had,” says Datta. 

The interface is also simplified. Datta explains that operators do not need extensive training to navigate settings. The design allows for intuitive control, reducing dependence on senior technicians. 

Energy efficiency feeds into operator confidence as well. Datta cites an Ultraflex configuration with eight-colour stations consuming 15 kW onwards depending on the settings and the dryers used. Lower energy usage reduces running costs, but it also means operators are not battling with load shedding or unstable power. This, he argues, is as much a human factor as a technical one.

Ultimately, the operator-centric approach reflects UV Graphic’s philosophy of engineering for local realities. Rather than assuming highly trained labour, the platform empowers operators to achieve precision without excessive intervention. Datta notes that this empowerment is not just technical but cultural. “When operators know they can manage a complex job, it changes the way they see themselves and the machine.”

AI-powered precision
Automation within Ultraflex is not just mechanical but increasingly digital. The press integrates servo control across all stations, ensuring that tension, register and die-cutting are synchronised. Datta highlights that such precision, often associated with imported machines, is now standard in their Indian platform.

The job recall system is an early form of applied intelligence, but UV Graphic is building towards more advanced AI-assisted diagnostics. Each module collects operational data that can be used for predictive maintenance. “We want converters to know when a lamp or roller is about to fail, not after it happens,” says Datta. This forward-looking approach reflects an ambition to integrate Industry 4.0 into the workflow.

Makeready waste is another area where precision matters. Datta stresses that Ultraflex achieves under ten metres of waste during setup, compared to the 200 metres often assumed in Western scenarios. “You cannot throw away expensive substrate here,” he says. 

Precision also extends to embellishment. The in-house developed screen, gravure units can deliver ink build-up of up to 80 microns, making tactile finishes possible inline. Braille, textured varnishes, and spot effects and embossing can be delivered without a second pass. 

For converters producing multiple SKUs, accuracy ensures first-time-right outcomes. Misregistration across jobs not only wastes material but can also lead to regulatory non-compliance in sectors such as pharmaceuticals. By embedding AI-enabled controls, Ultraflex reduces this risk.

Datta notes that customers have reported measurable reductions in turnaround times. “Some converters reduced end-to-end delivery from 72 hours to 16 hours,” he says. 

Hybrid curing flexibility
Ultraflex has been designed as a true hybrid platform, integrating flexo, screen, gravure, cold foil, hot foil and optional digital modules. This hybridisation is not an afterthought but part of the platform’s original engineering. “It’s not patchwork. It’s engineered integration,” says Datta.

One of the most distinctive features is the curing system. UV Graphic has developed hybrid curing units that can switch between mercury and LED lamps within seconds. This allows converters to balance cost and sustainability goals. “LED curing saves energy, but mercury still has its place for certain inks and coatings,” Datta explains. The flexibility ensures converters are not locked into a single technology. Datta highlights that this curing flexibility has been critical in winning customers in sectors like cosmetics, pharmaceuticals and liquor, where premium embellishments are common. Raised foiling, matte varnishes and tactile textures can be achieved in a single pass, without compromising drying quality. This capability reduces the need for multiple machines and streamlines operations.

Hybrid modules also allow converters to respond quickly to new market trends. For example, a converter can add a digital module for short-run personalised jobs without replacing the existing press. Datta notes that this adaptability is central to Ultraflex’s value proposition: “We give converters options that grow with their clients’ demands.”

The integration of multiple processes in one run enables converters to offer end-to-end premium labels. Datta explains that a whisky label with raised foil and matte varnish can be completed inline, reducing turnaround time and ensuring consistency. “That’s the difference between having modules engineered to work together and bolted on later,” he says.

Curing flexibility feeds into sustainability. By optimising energy use and reducing the need for multiple curing units, Ultraflex lowers both operating costs and environmental footprint. Datta positions this as part of a broader philosophy: “Sustainability is not a slogan. It is embedded in design choices.”

Beyond the buy
Datta emphasises that service is not an add-on but a strategic differentiator. “Our engineers are in Delhi, not Italy or China” he quips. For converters, this proximity translates into faster support and lower downtime. Remote diagnostics and on-site service within 12 hours are standard commitments and a 24/7 on line support is an assurance that the presses will never be down.

Spares availability is another pillar. UV Graphic manufactures its own frames and mechanical components, UV systems, plate mounters, print and magnet cylinders, ensuring full inventory for every installed machine. This eliminates the long delays often associated with imported parts. Datta recalls a customer who suffered a critical servo fault during a food label run. “We had the press running again in two hours,” he says. In comparison, waiting for European, Chinese parts would have meant a week of lost production time.

Training is also embedded in the service model. Every installation comes with five or more days of operator training, covering register control, print quality, tension calibration and error handling. Simulation of real jobs and fault diagnosis drills help operators gain confidence. For converters trying to upskill junior staff, this training is vital.

Datta frames service as a product feature rather than a separate function. Annual maintenance schedules with uptime guarantees and priority response times reinforce this philosophy. “Support is not an afterthought. It is part of the platform,” he says.

The company’s transparency also builds trust. Datta explains that customers know upfront what support they can expect. By avoiding hidden costs or vague commitments, UV Graphic positions itself as a reliable partner. This, he argues, has been critical in building a base of over 190 flexo installations and over 2,000 customers using other equipment.

Global market reach
Although Ultraflex was designed for Indian converters, the platform is attracting international attention. Datta notes that installations are expanding beyond India, with sales in USA, Europe, South America, Africa, Russia South Africa and Gulf Countries. 

Global competitiveness is not only about price but also about benchmarks. Datta argues that Ultraflex matches international standards in accuracy and speed, while offering a localisation advantage. “We deliver European quality at Indian responsiveness and price,” he says. This dual value proposition creates a unique position for UV Graphic in the market.

Global interest is further boosted by the hybrid features. Many overseas markets are also seeking flexibility in curing, embellishment and digital integration. Ultraflex’s modular architecture allows UV Graphic to customise for regional demands without redesigning the platform.

For Datta, the international journey is not about abandoning the domestic market but about building dual relevance. “India will always be our foundation,” he says.