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Closing one chapter, opening another: The year in review (Part I) — The Noel D’Cunha Sunday Column

Noel D'Cunha — Sun, 05 Jan 2025 05:00:00

Aaron Rego
Sales and marketing head, Brilliant Printers

Aaron Rego highlights Brilliant Printers’ winning edge

Looking back on 2024, Aaron Rego describes it as a year of significant activity and achievement. “We set ambitious goals, including building a new team, adopting advanced book printing and binding technologies, and implementing redundancy on the shop floor,” he notes. These initiatives, combined with green certifications and a focus on sustainability, led to a remarkable year-on-year revenue growth of 34%. The company’s ability to achieve these milestones reflects its commitment to innovation and operational excellence.

Rego highlights the evolving dynamics in the global printing industry as a critical driver of growth. “Customers worldwide are increasingly seeking options outside their existing print partners. This shift has created significant opportunities for Indian printers,” he explains. Brilliant Printers capitalised on this trend by enhancing its offerings and catering to a broader customer base.

Sustainability remained a top priority in 2024, with Brilliant Printers achieving a 50% increase in its Eco Vadis score and updating its credit rating. These advancements were driven by targeted investments in green initiatives, including reducing single-use plastics and adopting energy-efficient VFD-based utility equipment. By switching from fossil fuels to electric material handling equipment, the company successfully reduced its Scope 1 and Scope 2 carbon emissions by 47%.

Rego reveals ambitious goals for 2025, aiming to further reduce these emissions by 75% through retrofitting carbon emission devices on diesel generators, increasing solar energy usage, and implementing water conservation measures. Additionally, Brilliant Printers is working toward ISO 14001 and ISO 45001 certifications to enhance compliance and sustainability practices.

Technology and automation played a pivotal role in Brilliant Printers’ growth in 2024. Rego shares that the company invested in ERP systems, machine learning, and advanced software to streamline operations and improve efficiency. “Automation is at the core of our business, ensuring sustainability and efficiency. Our visit to Drupa in May 2024 provided valuable insights into emerging trends in digital printing,” he states. These advancements optimised processes and positioned the company to meet the increasing demand for high-quality, eco-friendly printing solutions.

Addressing the growing emphasis on eco-friendly packaging, Rego outlines Brilliant Printers’ approach to balancing sustainability with profitability. The company collaborated with suppliers to source materials with lower environmental impacts while maintaining functionality and aesthetics. “Currently, the majority of our products use renewable and recyclable raw materials,” he emphasises, reflecting the company’s commitment to environmentally responsible practices.

Looking toward 2025, Brilliant Printers plans to prioritise investments in automation, IT systems, and improved collaboration with key business partners. Rego stresses the importance of balancing innovation with cost efficiency, leveraging the redeployment of manpower and global supply chain management to maintain profitability. The company is also focused on building resilience to address potential challenges, including geopolitical uncertainties and the need for consistent quality and on-time delivery. “We continue to invest in capital expenditure, human capital, training, and process improvements to meet these challenges effectively,” he explains.

Resource allocation will play a key role in ensuring growth across emerging and mature markets. Rego highlights the importance of maintaining high-quality standards and meeting customer expectations to retain a competitive edge. “Innovation is essential, and our investments in this area will drive our growth in new markets while sustaining our position in established ones,” he adds.

To mitigate risks associated with supply chain disruptions, Brilliant Printers has developed tailored inventory-holding programs and advanced scheduling strategies. Rego emphasises the company’s proactive approach to operational resilience, ensuring that customers remain unaffected by global uncertainties.

Rego is optimistic about the prospects for 2025, predicting a year of growth for the print industry. He believes that Indian printers are well-positioned to capitalise on opportunities from overseas customers. “The key to success lies in implementing best practices across the value chain, maintaining product quality and delivery schedules, ensuring cost competitiveness, and prioritising sustainable practices,” he concludes. With a clear vision and robust strategy, Brilliant Printers is poised to thrive in an increasingly dynamic and competitive market.

Akshay Kanoria
Director, TCPL Packaging

As 2024 draws to a close, Akshay Kanoria describes the year as both demanding and rewarding. Despite a challenging macroeconomic environment, TCPL Packaging has significantly grown in volume and value terms.

A key milestone was the commissioning of a new printing capacity in Goa during the latter half of the year, complemented by the addition of balancing equipment across other units. Furthermore, the flexible packaging expansion undertaken in 2023 begins yielding tangible results, reinforcing TCPL’s strategic direction. “We are excited to be commissioning our greenfield unit near Chennai in February 2025, marking our entry into South India,” says Kanoria. The company also records a major achievement in Q2 FY25, surpassing Rs 400-crore in turnover within a single quarter for the first time.

Kanoria highlights TCPL’s ongoing investments in innovation and sustainability. “We continue to focus on R&D aimed at sustainable packaging solutions, both in the folding carton and flexible packaging segments. It is encouraging to see brands increasingly adopt these solutions,” he remarks. TCPL also takes strides in greening its operations by installing rooftop solar plants across all its factories, underscoring the company’s commitment to reducing its environmental footprint.

Reflecting on industry trends, Kanoria points to the continuing slowdown in consumption growth in India as a critical challenge. He emphasises the need for innovation and operational excellence to navigate this slower-growth environment. “The sustainability trend is also gathering momentum, and it reshapes the way we approach product development and customer engagement,” he adds.

Sustainability remains a cornerstone of TCPL’s strategy in 2024. The company positions itself as an innovator in plastic replacement within the paperboard packaging segment, leveraging advanced print effects and coating technologies. “We develop solutions that address the need for recyclable packaging in the flexible segment and continue to work closely with customers and suppliers to drive progress,” Kanoria explains.

On the technological front, TCPL enhances its digitalisation and automation capabilities. Efforts in 2024 centre on real-time data capture and improved reporting practices, although Kanoria acknowledges there is still significant room for improvement.

“These advancements are key to streamlining our operations and staying competitive in an increasingly digital world,” he says.

Looking ahead to 2025, Kanoria outlines TCPL’s investment priorities, including the commissioning of the Chennai folding carton unit and other capital expenditure plans yet to be announced. Maintaining and improving margins remains an ongoing endeavour, supported by diversification of the customer base, operational efficiencies, and a strong focus on innovation. “Sustaining margins is easier said than done, but it is a challenge we are committed to overcoming,” he asserts.

Kanoria also acknowledges broader industry challenges, including geopolitical uncertainties and the potential implications of global events, such as the Trump administration's return in 2025. Despite these headwinds, he expresses optimism about India’s position. “India is in a sweet spot, and we must not lose sight of that fact,” he affirms.

Resource allocation will remain a balancing act for TCPL, as the company seeks growth in emerging markets while maintaining its leadership in mature segments. Kanoria explains, “We are cautious with our investments, ensuring we don’t overextend ourselves while constantly scouting for new opportunities.” This pragmatic approach extends to risk management, where TCPL maintains a healthy debt-to-equity ratio and a diversified mix of customers and suppliers to withstand potential disruptions.

As for the outlook for 2025, Kanoria’s optimism shines through. “Every year is better than the last, and we remain confident in our ability to navigate challenges while capitalising on opportunities. The disruptions and chaos are part of the journey, but they also underline the resilience and potential of our industry,” he concludes.

Anuj Bhargava
Managing director, Kumar Labels

Anuj Bhargava advocates adapting for growth

Anuj Bhargava’s insights illuminate how the company is adapting to a hyper-competitive market and evolving customer expectations. In 2024, Kumar Labels focused on geographical consolidation, concentrating operations to optimise efficiency and capacity. “In these hyper-competitive times for the label industry, we planned geographical consolidation while adding capacity at a single location. We are expecting a conservative 12-15% increase in revenues along with an improvement in our bottom line,” Bhargava states. This strategy aligns with the company’s commitment to navigating industry challenges while maintaining growth.

The evolving preferences of consumers in Kumar Labels’ market have been a defining trend in 2024. “Customers want ease of operation at the lowest rates, and we are striving to meet these opposing demands,” Bhargava explains. This dual expectation has pushed the company to innovate and refine its offerings to stay competitive.

Sustainability continues to reshape the printing and packaging landscape, and Kumar Labels has taken notable steps in this direction. In 2024, the company launched two major solutions aimed at making its pressure-sensitive adhesive (PSA) labels 90% circular. “We expect to roll these out in larger quantities,” Bhargava shares, reflecting the company’s proactive stance on eco-friendly solutions.

The adoption of new technology has been another cornerstone of Kumar Labels’ strategy. The company implemented a new ERP system in 2024, providing enhanced control over processes for customers, service providers, and suppliers. “This technological upgrade streamlines our operations and strengthens our ability to deliver consistent quality and service,” Bhargava remarks.

Kumar Labels has also maintained compliance with evolving regulatory requirements for eco-friendly packaging. Bhargava underscores the company’s commitment to adapting as these needs evolve, ensuring both compliance and product differentiation.
Looking ahead to 2025, Kumar Labels’ investment priorities reflect a balanced approach. “We invest in alternate years, and 2025 is expected to be low on investments. Our focus will be on improving the bottom line and driving revenues from recently made investments,” Bhargava explains. The company aims to enhance profitability while maintaining growth by maximising returns from past investments.

The challenges for 2025 include maintaining margins while scaling up in a fragmented market with changing workforce preferences. Bhargava acknowledges that offering sustainable products will remain a long-term challenge but is confident in the measures Kumar Labels has implemented to address these issues effectively.

While Kumar Labels will concentrate on its current market in 2025, the company is also mitigating global supply chain disruption risks. “Our patented offering will reduce our dependence on imports,” Bhargava notes, highlighting a strategy that strengthens operational resilience.

The outlook for 2025 is optimistic. Bhargava envisions concentrated efforts from a unified operation, focusing on sustainable offerings, better margin realisation, and higher revenues. “We expect that the efforts put in during 2024 will lead to a brighter 2025 and beyond,” he concludes. With a clear strategy and commitment to innovation and sustainability, Kumar Labels is well-positioned for continued success.

B Manoharan
Executive director, Hitech Print Systems

Reflecting on the key milestones of 2024, B Manoharan highlights significant technological investments that have bolstered Hitech’s operations. “We added a nine-colour Rotatek Machine for secure base stationery, catering to government departments, and a high-speed inkjet printer for personalised OMR sheets, which are increasingly in demand as the industry shifts towards digital solutions,” he notes.

These advancements have strengthened Hitech’s ability to support its core focus on the education sector, meeting the needs of universities and institutions migrating to digital on-screen marking (OSM) and data-capturing solutions.

The education sector remains a primary driver for Hitech, with substantial demand for OMR forms and unique page-barcoded booklets. Manoharan observes that many universities and institutions are yet to embrace digital transformation, providing a significant growth opportunity fully. “The potential in this sector is vast, and we are positioned to cater to its evolving requirements,” he states.

Sustainability has been another focal point for Hitech Print Systems in 2024. The company adopted process-free offset plates across its plants, eliminating the use of alkaline developers and reducing power consumption. A 70KVA solar power system was installed at the Andhra Pradesh facility, reflecting Hitech’s commitment to renewable energy. Additionally, the company implemented a recycling initiative, converting waste food and garden trimmings into vermicompost manure for its plants. “Sustainability is at the core of our operations, and these measures are steps towards a greener future,” Manoharan remarks.

In 2024, Hitech also introduced blockchain technology QR codes for verification and authentication in university degrees. Manoharan describes the initiative as a success, with two universities already adopting the technology and more expected to follow in 2025. “This innovation addresses the critical need for secure and tamper-proof credentials, and the response so far has been overwhelmingly positive,” he adds.

Adapting to the increasing demand for eco-friendly solutions, Hitech has shifted its focus to digital printing for short-run, personalised orders. Manoharan explains that universities’ move towards autonomy has led to a shift from bulk orders to smaller, more frequent ones. “By transitioning offset printing jobs to digital, we can meet these demands with shorter turnaround times, reduced wastage, and improved profitability,” he notes.

Looking ahead to 2025, Hitech plans to invest further in digital printing technology to enhance its personalisation capabilities. Manoharan emphasises the importance of balancing innovation with cost efficiency, stating, “We aim to convert offset jobs to digital with personalised elements, ensuring cost-effective and profitable solutions.” The company is also prioritising R&D to develop tailored solutions for its customers, ensuring continued relevance in an increasingly dynamic market.

Manoharan anticipates several challenges for the printing and packaging sector in 2025, including the growing demand for personalisation, on-demand delivery, and smaller print runs. He believes digital printing and conversion will play a critical role in addressing these trends. “By focusing on these areas, we can deliver solutions that meet the evolving needs of our clients while maintaining operational efficiency,” he asserts.

Hitech has established operations in two states to mitigate risks associated with supply chain disruptions and economic uncertainties and is prepared to expand to other locations based on customer needs. “Proximity to major customers ensures faster delivery and greater resilience against logistical challenges,” Manoharan explains.

As for the outlook for 2025, Manoharan is optimistic. He sees a growing willingness among customers to adopt new technologies for process automation, creating opportunities for print solution providers to offer enhanced services. “Globally, the technology landscape is advancing rapidly, enabling us to deliver more value to our customers. 2025 promises to be a year of growth and innovation for the industry and Hitech Print Systems,” he concludes.

Dharmesh Mehta
CEO, Reliable Prints

With a focus on innovation, sustainability, and adapting to evolving market trends, Dharmesh Mehta provides insights into how Reliable Prints is navigating the dynamic landscape of the printing industry.

In 2024, Reliable Prints prioritised upgrading its capabilities and developing new verticals to diversify its offerings. “The print industry demands constant innovation and evolution, and we have made it our mission to address these aspects,” Mehta states. The company’s focus on these initiatives aligns with the industry’s transition towards shorter print runs, a shift that has been accelerated by the pandemic. As a player in the digital print space, Reliable Prints has found this transition fruitful, further boosted by the success of its online web store in acquiring new clientele.

Sustainability is increasingly influencing client expectations and industry practices, and Reliable Prints has made significant strides in this area. Mehta highlights the company’s use of 100% recyclable paper media and its commitment to upgrading equipment to reduce emissions and utilise green inks. “Clients are becoming more aware of sustainability, and we ensure our processes and media meet eco-friendly standards,” he explains.

Technological advancements have also been pivotal in Reliable Prints’ growth. With over three decades in the digital print industry, the company continues to refine its operations and SOPs. In 2024, the focus shifted towards automation in post-press applications, a move aimed at enhancing workforce efficiency and product quality. “Automation will allow us to utilise our resources better and elevate the quality of our offerings,” Mehta adds.

Although Reliable Prints primarily operates in the general commercial printing space, Mehta acknowledges the challenges posed by regulatory frameworks prioritising eco-friendly practices. He points out the difficulties in accessing affordable substitutes for traditional materials, noting that achieving balance will require collaborative efforts from media manufacturers and consumers alike.

Looking ahead to 2025, Reliable Prints plans to continue expanding its verticals while enhancing post-press capabilities. Mehta reveals that the company is exploring options for new equipment and implementing an MIS system to fine-tune processes and improve data-driven planning. “Investing in better technology and processes will ensure we remain competitive and prepared for future challenges,” he states.

The printing sector faces ongoing challenges, including shifting consumer behaviours and competition from disruptive players. Mehta underscores the importance of innovation, quality assurance, and a tailored approach for each client to sustain growth. “Our strategy revolves around the three major T’s: Technology, Training, and Time management,” he explains, emphasising the need for a balanced allocation of resources.

To address supply chain disruptions and economic uncertainties, Reliable Prints is strengthening its backup processes and reserving resources for reinvestment or emergency acquisitions. Mehta highlights the importance of inventory management and real-time information as critical tools for effective planning. “Having robust systems in place will enable us to navigate potential disruptions with resilience,” he says.

Looking forward to 2025, Mehta expresses optimism for the year ahead. “The past few years have been about consolidation and sustenance. We are hopeful that our efforts during this period will bear fruit in the coming year and benefit the entire print fraternity,” he concludes. With a clear focus on innovation, sustainability, and operational excellence, Reliable Prints is poised to make significant strides in 2025.

Himanshu, Rahul, and Karan Kapoor
Directors, JK Labels

Himanshu, Rahul, and Karan Kapur, directors of JK Labels, reflect on their journey through 2024 and outline their strategic vision for 2025.

Reflecting on 2024, the Kapurs emphasise their focus on quality over volume growth. “We are ever-evolving in quality and have now received the SEDEX 7.0 four-pillar certification. We’ve also enhanced our capability to comply with export norms,” they state. By prioritising quality growth, JK Labels continues to set itself apart in an increasingly competitive industry.

The Kapurs note that the printing and packaging industry is witnessing significant shifts. The new generation of businesses is willing to experiment with innovative materials to enhance packaging appeal. However, the influx of Chinese and Indian machines has drastically reduced capex costs, leading to a surge of new entrants in the market. “This has caused bottom lines to plummet to unsustainable levels,” they observe. Established firms are now navigating challenges like falling prices, market disruptions, and supply issues caused by backward auctioning practices.

Sustainability remains a key focus for JK Labels. In 2024, the company took several steps to reduce its environmental impact. “We installed an LED curing system to minimise our environmental footprint, replaced all HVAC systems with newer, energy-efficient ones, and continued to prioritise recycling and reusing,” the Kapurs share. They view sustainability as an evolving responsibility and are committed to exploring new methods for continuous improvement in the years ahead.

Digitalisation and automation have been central to JK Labels’ strategy. The Kapurs highlight the interdependence of automation and skilled human labour in producing superior-quality products. “We give equal importance to both aspects and continue to invest in better machinery while building a strong team,” they explain. These efforts ensure the company’s operations remain efficient and innovative, meeting the demands of a competitive market.

As regulatory frameworks and consumer behaviour increasingly prioritise eco-friendly packaging, JK Labels collaborates closely with material vendors to stay ahead of industry requirements. “This ongoing communication helps us align with client needs in sectors like pharmaceuticals and food and beverage, enhancing our overall efficiency,” the Kapurs note.

Looking to 2025, JK Labels plans to increase its investments in ancillary machines to improve operational efficiency. The company is also exploring opportunities to acquire core machines essential for future growth. “Our machine suppliers have been highly supportive in providing us with the latest information, which helps us make informed decisions,” they add.

The Kapurs identify changing consumer trends as a major challenge for 2025. To address this, they stress the importance of engaging with customers to anticipate future demands. In addition, JK Labels leverages its distribution networks in emerging markets to gain valuable insights into regional requirements, ensuring its offerings remain relevant and competitive.

JK Labels has adopted a proactive approach to mitigate risks associated with supply chain disruptions. “We keep our customers informed about potential delays and help them maintain adequate inventory levels,” the Kapurs explain. This transparency strengthens client relationships and ensures operational resilience.

The outlook for 2025 is optimistic. “As one of the top emerging markets, we believe new opportunities for growth and scaling will continue to arise,” they conclude. With a steadfast commitment to quality, sustainability, and innovation, JK Labels is well-positioned to thrive in the coming years.

Binding the inkjet future: Short-run book production in India

Noel D'Cunha — Wed, 18 Dec 2024 13:06:00

The demand for short-run book printing in India has grown significantly in recent years, driven by the rise of digital platforms and eCommerce. This shift caters to diverse needs across self-publishing, corporate manuals, and educational materials, with newer segments such as “self-publishing academic institutions” adding further momentum.

Straits Research shows India’s print-on-demand market is expected to grow at a compound annual growth rate (CAGR) of 27.8% between 2023 and 2031. However, P Sajith, managing director at Bindwel, argues that this projection might underestimate the sector’s potential. “Given the low base we are starting from, the actual growth might be much faster. Short runs of 50–1,000 copies and micro runs of fewer than 50 copies are becoming the norm,” he observes.

As the focus shifts towards customisation and on-demand production, the transition from traditional sheetfed printing to inkjet technology is accelerating. In all this, inkjet printing is being recognised for its ability to meet the demands of short-run printing. Sajith points out that “customisation is now a key driver, with inkjet making it easier to deliver personalised content.” He adds that the technology eliminates plate-making and set-up costs, which reduces expenses for small-batch production. Furthermore, print-on-demand capabilities mean there is no need to stockpile books, eliminating storage costs and the risk of waste from overproduction. “The faster turnarounds offered by inkjet align perfectly with the dynamic nature of today’s publishing industry,” Sajith notes.

Overcoming bookbinding challenges

Despite advancements in bookbinding techniques, the processes associated with short-run projects face distinct challenges. Traditional techniques are often ill-equipped to handle the variability in book sizes and formats required for short-run production. Frequent job changeovers can lead to inefficiencies, while higher wastage levels become particularly problematic for smaller runs. Also, there is the issue of integrity checks, such as ensuring the correct covers are paired with their respective book blocks. Sajith elaborates, “Imagine a short-run book printer managing 25 titles in a single day. If the binder takes 15–20 minutes to change from one job to another, that’s an entire shift lost to changeovers. Binding systems must evolve to enable changeovers in under a minute to keep pace with demand.”

Modern binding solutions are beginning to address these issues by offering greater integration with inkjet printing workflows. Advances now allow signatures to be processed as cut sheets or with minimal folding, streamlining binding operations. Enhanced automation ensures accurate job understanding and format alignment, reducing errors and downtime. According to Sajith, “The binding system—whether inline or offline—must be capable of adapting to the fast-paced requirements of short-run projects. The ability to seamlessly switch between jobs in minimal time is critical.”

Inkjet printing technology has made strides in improving its compatibility with bookbinding. High-resolution output, precision ink application, and improved compatibility with a range of substrates ensure that the prints are durable and vibrant, making them ideal for high-quality binding. “The reduction in consumables costs has also made inkjet printing more accessible and viable for many businesses,” Sajith notes.

When it comes to cost-effectiveness, inkjet technology holds an edge for runs under 1,000 copies due to its lower set-up costs and faster changeovers. However, offset printing remains more economical for larger volumes. Sajith recommends a hybrid approach, saying, “Combining inkjet for short runs with offset for high-volume projects allows publishers to optimise production costs while maintaining quality across various scales.”

The return on investment for adopting modern bookbinding solutions is another factor driving their adoption. Faster turnarounds, reduced waste, and lower inventory requirements translate into clear financial benefits. Additionally, the ability to customise products opens doors to niche markets such as self-publishing and educational institutions. “Investing in modern binding systems isn’t just about efficiency. It’s about creating new opportunities and staying competitive in a rapidly evolving market,” Sajith explains.

Emerging bookbinding technologies

With the increasing demand for short-run book printing in India, there is a growing need for systems that enable rapid transitions between different run lengths and automate adjustments for various book formats.

According to Sajith, advanced systems like Bindwel’s Freedom 2K and Insta One-Book models are specifically designed to address these requirements. “With these solutions, print service providers can seamlessly adapt to the fast-changing requirements of short-run and on-demand printing,” Sajith explains.

Bindwel’s Insta

While Bindwel is the only India-based manufacturer of bookbinding equipment for short-run and on-demand solutions globally, solutions from Horizon, Muller Martini, and Meccanotecnica are also available.

Sajith announces that Bindwel is set to introduce the Trimit 30C SRT, a new trimming system aimed at enhancing on-demand book production. He remarks that this represents a significant advancement in efficiency: “This solution will enable precise trimming of books on demand, thereby improving the workflow for inkjet-printed books.”

Bindwel’s Trimit 30C SRT

The integration of automation in these systems not only streamlines production but also enhances scalability. Sajith notes that Bindwel’s Freedom 2K is ideally suited for short runs starting from 10 copies, while the Insta model is tailored for micro runs, including one-off projects. “These machines are built with the future of short-run printing in mind, where flexibility and precision are paramount,” he adds.

Importance of quality and automation

While speed and adaptability are crucial, the quality of bookbinding remains a cornerstone for ensuring professional standards in short-run printing. Sajith highlights the role of careful planning in maintaining quality, emphasising factors like grain direction, adhesive strength, and precision trimming. “The grain direction should always be parallel to the spine for both the inside pages and the cover to prevent warping,” he explains. Additionally, new-generation adhesives such as PO [full form] and polyurethane reactive (PUR) grades provide the durability required for modern binding.

Precision trimming is another critical aspect, especially when dealing with varied formats. Sajith points out that automated systems like Bindwel’s Trimit 30C SRT and Freedom 2K ensure consistency in spine preparation and adhesive application, which are essential for maintaining a professional finish. “Our technology is designed to integrate seamlessly with digital workflows, making it easier to meet the exacting standards of short-run and on-demand printing,” he says.

Automation also plays a pivotal role in addressing the growing demand for customisation. Features like quick job changeovers, QR code integration for personalised orders, and high-speed binding are key to meeting the requirements of short-run projects. “Automation is no longer a luxury; it’s a necessity,” Sajith emphasises. “With Bindwel’s Insta model, for instance, micro runs and one-off books can be produced efficiently without compromising on quality.”

Team Bindwel

From five to 5,000 copies

Bindwel’s Freedom 2K stands out as a versatile solution for short-run printers, offering seamless transitions across run lengths ranging from as few as five copies to as many as 5,000. According to Sajith, advanced automation makes this capability possible, including job-switching and size adjustments. “The Freedom 2K minimises downtime while supporting diverse project requirements, which is crucial for short-run printers,” he explains. The system also includes a thickness measurement device, providing an additional layer of quality assurance by detecting variations in paper bulk or GSM. Sajith adds, “This feature complements the metadata checks, ensuring precision and consistency.”

The machine is already operational in two leading Indian print facilities, SAP Print Solutions in Mumbai and Saurabh Printopack in Noida. “At SAP, the Freedom 2K handles loose leaves, while at Saurabh, it processes folded signatures, showcasing its adaptability across different workflows,” Sajith notes.

For micro runs and highly personalised projects, Bindwel’s Insta One-Book model offers unparalleled flexibility. Capable of producing up to 1,000 books per hour, each uniquely customised, the Insta integrates seamlessly with modern inkjet workflows. Sajith highlights the use of QR code reading for both the book block and the cover, ensuring accuracy and efficiency. “This capability makes Insta an ideal solution for on-demand printing, where every book can be different,” he says.

Sustainability and hybrid production

Bindwel’s innovations are not limited to production efficiency but align with the industry’s growing focus on sustainability and cost optimisation. The Trimit 30C Freedom SRT exemplifies this commitment with its adaptive knife movement and precision cutting, which reduce errors and waste. “Features like these are critical for maintaining a professional finish in short and micro runs while minimising material wastage,” Sajith explains.

Bindwel also promotes a hybrid production model, combining offset printing for high-demand titles with digital solutions for niche and short-run projects. Sajith underscores the advantages of this approach, saying, “Our hybrid model optimises costs and minimises waste while meeting the diverse needs of Indian publishers and self-publishers. The Freedom 2K, paired with the Trimit 30C SRT trimmer, is ideally suited for such applications.”

Sustainability remains a key focus for Bindwel, with solutions designed to reduce overproduction and optimise resource usage. Machines like the Insta and Freedom 2K enable just-in-time production, helping minimise inventory holding costs and material waste. Sajith concludes, “Our approach ensures that only the required quantity is printed and bound, contributing to both environmental goals and operational efficiency.”

With the evolution of the Indian printing industry, Bindwel’s bookbinding technologies are set to revolutionise the sector by providing scalable, sustainable, and affordable solutions that meet the needs of contemporary publishing.

ITC's path for value-creation, innovation and sustainability

PrintWeek Team — Fri, 15 Nov 2024 14:05:00

Having spent most of my career with ITC in the paper division, stepping into the printing business two years ago has been a dynamic shift. This opportunity opened a new chapter for me, and today I should address an association as storied as the Pune Press Owners Association (PPOA), established in 1919. The rich legacy of ITC’s printing division began in 1925 in Munger, Bihar, primarily to meet the packaging needs of our products, particularly in the tobacco sector. As ITC approaches its centenary in the printing business, it is the perfect moment to reflect on how far we have come and where we are heading.

Printing, like any sector, demands continuous reinvention. The 2000-2020 years saw significant investment in technology across the industry, particularly in offset printing, which dramatically increased competition. The liberalisation of the Indian economy coupled with booming sectors like pharmaceuticals changed the game. Regions like Himachal Pradesh and Uttarakhand opened up, transforming the business landscape.

At ITC, we have always taken a long-term view. We don’t plan just for the next year but for the next five. Market signals, customer needs and innovation must inform your roadmap if you aim to stay ahead. For any business, I strongly recommend setting a six- to seven-year vision. Where do you want to be? What markets are ripe for expansion? What strengths can you leverage and where should you focus your growth? Whether you are a sole proprietor or have a senior leadership team, these discussions are critical to ensuring alignment and focus on long-term goals.

At ITC, one of our specialities has been liquor packaging, particularly with our expertise in design, pre-press, metallic and tactile finishes. We have won several accolades for this, but in recent years the industry has moved towards reducing secondary packaging for liquor, except for limited editions. This shift forced us to rethink our approach, and it is an important lesson: no matter how specialised your offering is, the market can change in unexpected ways, as category leaders make commitments on sustainability. At ITC, we have achieved FSC certification for our paperboards and operate our liquor packaging manufacturing on 80% renewable energy.

Despite these efforts, the push for less packaging has prompted us to adapt, finding ways to meet market demands while maintaining our commitment to sustainable practices. When discussing business strategy, differentiation becomes crucial. In printing, many fall into the trap of competing solely on cost. This can lead to commoditisation. Instead, businesses should focus on delivering value— whether through unique design, post-print enhancements or efficient and unique services. Offering more circular solutions is a new driver for our business.

Understanding what customers truly need and offering a value proposition that sets you apart, can ensure you remain competitive. Investments in specialised equipment, while important, are not the only way to gain an edge. Strong relationships with suppliers, for instance, can lead to co-developing solutions that create a market advantage. Additionally, knowledge and experience gained through years in the industry are irreplaceable assets. These intangibles give you a strategic edge that competitors may struggle to replicate. Operational excellence is another key pillar of success. Before rushing into new investments, it is essential to optimise current operations. Collaborating closely with customers can also lead to innovations and cost savings that benefit both parties. A deep understanding of your operations, including the efficiency of machinery, can unlock hidden capacity and improve productivity. Digital enablement of operations can raise productivity levels , reduce wastages and energy consumption.

Sustainability, as I have mentioned, is a critical area where businesses must take proactive steps. Understanding your carbon footprint, from direct to value chain emissions, will be vital in the coming years, especially as regulatory pressures like carbon taxes become a reality. Setting clear sustainability targets and investing in renewable energy, such as solar power, can bring both environmental and economic benefits. The printing industry is at a crossroads where those who anticipate change, adapt strategically and integrate sustainability into their operations will thrive. Focusing on operational efficiency, building strong supplier relationships and investing wisely will set the stage for long-term success.

President Speak: Navin Kotadia

PrintWeek Team — Thu, 03 Oct 2024 11:30:00

Congratulations on your recent election as the president of RPPA.
Thank you. It’s been three months since the new core team took over. We’ve entered the second term of RPPA, and we have a strong core team of printers working effectively.

What’s the latest update on your association?
Our association, comprising over 106 members from diverse sectors like trading, printing, packaging, and design, is focused on addressing community and market changes. Our members work for direct clients as well as take job works from designers who design print material and packaging.

There is also another association in Rajkot, the Commercial Printers Association, with offset printers, screen printers and freelancers, and designers as members. It’s an association which began in 2007 but isn’t as active as an association should be. RPPA was established in 2017 with an agenda to work cohesively, bringing technological trends and market developments in the printing arena to the knowledge of the association members as well as sales-driven conversations.

We hold technical board meetings to discuss MSME schemes and act as a mediator between the government and industry. Additionally, we use a WhatsApp group to share technical information through PDFs and videos.

What are your current focus areas for improving the community?
We are working on supporting lower-level businesses, particularly second-generation printers, by fostering face-to-face interactions and awareness. It’s crucial to enhance market reputation and value through effective packaging.

We hold technical board meetings to discuss MSME schemes and act as a mediator between the government and industry. Our goal is to share information on the benefits of these schemes, and how best they can be implemented.

Additionally, most of our members are second-generation businessmen, so they use a WhatsApp group to share technical information through PDFs and videos. We also have many designers, especially freelancers working in B2B, whose talents we want to leverage. While our printer members deliver quality, our current focus is on driving innovation.

In November-December 2024, we are planning to host a conference, which will have knowledge sessions as well as networking opportunities.

What are your thoughts on partnerships between printers?
It is crucial, as combining expertise from different fields can lead to successful collaborations. We aim to expand infrastructure, manpower, and technology through these partnerships. RPPA encourages a collaborative business concept, which I think is key to reducing competition and enhancing innovation, provided we maintain a better structure and mindset, even if the platforms differ. To give you an example: We have a membership of 106. If individually we compete, each one will have 105 competitors. If three members with different expertise and strengths collaborate, the competition is down to just 30.

How do you manage price pressure?
Price pressure varies across different categories and client requirements. The reason is that each print service provider has his unique strengths, it may be the ability to print quickly, or use its post-press strength to create an innovative box. The question of price pressure does not arise. Industries such as hardware foundries, kitchenware, and automobiles are driving its economy. There is neighbouring Jetpur, another industrial hub, and of course, Morbi, which is 60-km away from Rajkot. All these industries are driving the demand for print and packaging. With a growing market, there’s space for everyone.

What’s Rajkot print service provider USP?
Our USP is centred on packaging, but we also handle a significant amount of commercial work.

Unfortunately, Rajkot’s print and packaging industry has still not emerged from the shadows of Ahmedabad and Vadodara, despite the kind of quality it produces. You will be surprised, that there are many award-winning print and packaging jobs, which get their finishing touches in Rajkot.

Did your association members travel to Drupa?
Yes, our association partnered with a travel and tour company and flew 22 members to Drupa.

What feedback did you receive from Drupa?
The feedback was positive, with many discussions focused on digitalisation and gravure flexibles.

What is the trend you observed at Drupa?
We observed that the print and packaging market is booming, especially with a significant rise in demand for labels. This underscores the growing need for automation/digitalisation, flexo, and labelling solutions.

What is the distribution of printer sizes in Rajkot?
Rajkot is a hub for the print and packaging industry, boasting around 200 firms. The top 10 companies have a turnover ranging from Rs 25- to Rs 30-crore, positioning them as large print and converting firms with over two multi-colour presses.

Additionally, approximately 40 firms with turnovers between Rs five- and Rs 10-crore are equipped with one or more four-colour presses. Furthermore, there’s a cluster of about 50 small print and converting firms with either two-colour or single-colour presses and a turnover of under Rs three to Rs five-crore. Moreover, around 100 screen printers and designers have turnovers in the Rs 1-crore range. The designers depend on the print-packaging converters and screen printers to actualize their designs.

How many four-colour printers are there in Rajkot?
There are approximately 400 four-colour printers in Rajkot. Around 10% are new, while the rest are older, established ones.

What is Rajkot known for that others might not be aware of?
Gujarat is renowned for its high-quality micro embossing jobs, which is a unique strength in the region.

What are the upcoming targets for your association?
Our targets include increasing membership with a focus on quality, advancing technology and professionalism, and shifting traditional mindsets to more professional approaches. We also plan to set up a system with scheduled meetings on specific topics and trending conversations.

Four industry presidents eye efficiency and growth: The Noel D'Cunha Sunday Column

Noel D'Cunha — Sat, 31 Aug 2024 21:34:00

Ashish Agarwal — Ayodhya (Faizabad) Printers Association

PrintWeek (PW): What was the first thing you did when you got the news?
Ashish Agarwal (AA): The establishment of the Ayodhya (Faizabad) Printers Association (AFPA) felt like a dream come true. I'm deeply grateful to Professor Kamal Mohan Chopra for his guidance and dedication to advancing the printing and packaging sector in India. Upon becoming the first president of the AFPA, my initial idea was to assess the situation, identify the challenges faced by printers in the twin cities, and set a strategic response in motion.

PW: What is the first thing on your agenda?
AA: My top priority is to foster a network among printers, emphasising the power of unity and collaboration. Inspired by our mentor, Professor Chopra, I want to explore the potential of establishing a cluster that benefits all regional printers. Additionally, we are committed to ensuring all stakeholders are well-informed and aligned with our shared vision, setting a clear course to tackle challenges and seize new opportunities.

PW: Who are your team members?
AA: I'm honoured to have the support of esteemed figures in Ayodhya's printing community, including Savrender Vikram Singh, Jai Parkash Pandey, and Girdher Agarwal as patrons of AFPA. Our executive team consists of Abdul Aziz Khan as vice president, Ramesh Jaiswal as general secretary, Shubechu Tiwari as treasurer, and Ram Tirath Sahu as organising secretary. Together, we bring a wealth of expertise in finance, operations, marketing, and customer relations, crucial for driving our strategic goals.

PW: What is your plan for the next 12 months?
AA: As a newly formed association, our plan for the next year is to promote the benefits of joining AFPA and the power of networking. We intend to launch initiatives that stimulate growth, enhance operational efficiency, and build stronger relationships with clients and partners. Our goal is to innovate and adapt to the changing market landscape, ensuring that our members thrive.

PW: Please give us a sense of the print and packaging industry in Ayodhya. The size and the break-up between offset and digital print?
AA: Although the printing industry in Ayodhya is currently modest, the city's rapid development as a major religious centre presents significant growth opportunities. The industry is a mix of traditional offset printing, which remains prevalent due to established infrastructure, and digital printing, which is increasingly favoured for its flexibility and cost-effectiveness.

PW: How has the industry in Ayodhya benefited from the recent Lok Sabha elections and Ram Mandir tourism?
AA: The recent Lok Sabha elections and the surge in tourism around the Ram Mandir have provided a substantial boost to our industry. The influx of visitors has led to a higher demand for printed materials, fueling business growth and opening up new avenues for expansion.

PW: There is huge uncertainty about the cost of raw materials. How are your members and their factories coping?
AA: Previously, printers in the city operated independently, often with limited knowledge of market dynamics. Now, with the formation of AFPA and the guidance of Professor Chopra, we are exploring joint purchasing of raw materials to leverage bulk discounts. This strategy, along with diversifying supplier bases, adjusting pricing, and optimizing production processes, helps our members better manage the volatility in raw material costs.

PW: What kind of conversations are you having with your customers in UP?
AA: We are actively engaging with our customers to understand their evolving needs and address any supply chain challenges. Our conversations also focus on exploring new ways to collaborate, ensuring we meet and exceed their expectations in this dynamic market.

PW: One trivia about Ayodhya that outsiders don't know about?
AA: While Ayodhya is celebrated for its rich historical and cultural legacy, few people know that it was once a thriving hub of trade and commerce. This vibrant past has left a lasting impact on the city's cultural and economic landscape.

PW: As president of the association, what is your message to the fraternity for the future?
AA: My message is to stay adaptable and embrace innovation. By adopting new technologies and fostering a spirit of collaboration, we can build a resilient and thriving industry. Let's work together to create a brighter, more prosperous future for all. Finally, I would like to conclude by saying, “Ayodhya, a city steeped in tradition, continues to inspire with its sacred river Sarayu flowing from the north.”

Raanu Bisht — Devbhoomi Printers and Publishers Association, Dehradun

PrintWeek (PW): What is the first thing on your agenda?
Raanu Bisht (RB): My top priority is to educate and train team members on Government eMarketplace (GEM). Many in the printing industry, particularly those working with government contracts, struggle because all obligations must be met through GEM. Enhancing technical literacy is essential for effective participation in GEM. Also, the government policies at the state level need to be studied and if any intervention is required, then it has to be addressed.

PW: What is your plan for the next 12 months?
RB: Our goal is to join the All India Federation of Master Printers (AIFMP). Our next step involves connecting with more printers and publishers in our state to establish a robust organisation. We aim to motivate our members to engage in print competitions, organise interactive sessions, and arrange meetings with GST officials to address any concerns.

PW: We are aware of Zircon but can you give us a sense of the print and packaging industry in Dehradun?
RB: We have more than 100 offset printers in Dehradun engaged in commercial printing and job work. Some are into publishing also. But there are very few printers for packaging. To name a few, Alpine Industries, Shakumbhari Packaging, and Anil Enterprises. Dehradun has huge potential for the packaging industry, thanks to its geography and its development. Also, the government facilitates investors and entrepreneurs with its enduring policies.

PW: How was Dehradun impacted by the recent landslides and floods?
RB: Our city has been minimally affected by the recent landslides and floods, primarily impacting the peripheral areas along the riverbanks. The most significant impact has been felt in the mountain region.

PW: There is huge uncertainty about the cost of raw materials. How are your members and their factories coping?
RB: Dealing with increased raw material costs and uncertainty in the printing industry requires a strategic approach. We explore alternative vendors for raw materials to negotiate better prices. Trying to optimise material usage by implementing efficient printing processes and reducing waste. The members are passing on increased costs to customers through price adjustments. Some are also maintaining optimal inventory levels to avoid overstocking and renegotiating contracts with suppliers. We all are eyeing and monitoring market trends to adjust strategies accordingly. All of us have felt the significant effects of last year's price increases, particularly in paper prices. As a result, many of us are being extra careful when providing quotes.

PW: What kind of conversations are you having with your customers?
RB: At Samaya Sakshaya, our conversations with customers are focused on understanding and realising their unique visions through detailed discussions that capture the essence of their ideas and goals. We emphasise fair trade practices, transparent and fair pricing, and responsible sourcing to ensure ethical operations and environmental sustainability. By delving into technical aspects like paper types, printing techniques, and design elements, we align every detail with the client's expectations, offering expert advice to enhance the final product. Our collaborative approach fosters strong partnerships, keeping clients informed at every stage and building lasting relationships based on trust, quality, and a shared commitment to excellence.

PW: Any steps taken by the Devbhoomi Printers and Publishers Association, Dehradun with the government?
RB: The Devbhoomi Printers and Publishers Association has had a meeting with the GST Council regarding the issues of taxation percentage and to keep the association informed about any changes in the policy regarding GST. The team met then-chief minister Trivendra Singh Rawat regarding the cancellation of calendar and diary printing in the State Government department. We have had a conference where the higher officials from the industries department enlightened the members regarding the MSME and other industrial policies. It allowed looking into the existing schemes, policies, and initiatives supporting our industry.
Our association is trying to prepare a strong case with facts and data about the printing and packaging industry’s potential, challenges and growth opportunities in our state to have them back us.

PW: One lesson you have learnt from the past 40 months?
RB: One valuable lesson I have learned over the past 40 months is the importance of adaptive leadership and effective communication. Navigating various challenges, especially during unpredictable times, has reinforced the need to stay flexible and open-minded as a leader. Embracing change and being willing to pivot strategies when necessary is crucial for maintaining the resilience and growth of an organisation. Additionally, fostering transparent and empathetic communication within the team has proven essential for building trust, encouraging collaboration, and ensuring everyone is aligned with our vision and goals. These experiences have underscored the significance of leading with agility and compassion to drive sustained success.

PW: As president of the Devbhoomi Printers and Publishers Association, Dehradun, what is your message to the fraternity for 2024-25?
RB: My message to the fraternity for 2024-25 is one of unity, innovation, and resilience. In the face of evolving industry dynamics, we must embrace new technologies and sustainable practices to stay competitive and environmentally responsible. Collaboration and knowledge-sharing among members will be key to overcoming challenges and seizing opportunities. Let's continue to support each other, uphold the highest standards of quality and ethics, and work collectively towards advancing our craft. Together, we can inspire positive change and ensure the continued growth and success of our industry.

Rahul Marulkar — Poona Press Owners Association

PrintWeek (PW): How has the print and packaging industry in Pune coped with challenges like recent flooding and traffic disruptions?
Rahul Marulkar (RM): Fortunately, most printing facilities in Pune are located away from flood-prone zones and in gated industrial areas, which helped mitigate the impact of the recent floods. Traffic disruptions are normally managed by planning deliveries considering the traffic conditions and, if possible, in compact or smaller vehicles. However, the unforeseen power outages during heavy rains pose a big challenge.

PW: With the rising costs of raw materials, how are your members managing?
RM: The fluctuating costs, especially of paper, are indeed challenging as they account for a significant portion of our supply chain expenses. We are keeping our customers informed about the validity of cost estimates, which helps in managing expectations and financial planning.

PW: In what way?
RM: The PPOA is also helping its members supply ink and other binding raw materials at heavily discounted prices by adopting its bulk buying principle which has been practised for many years now through our project - Mudran Sahitya Bhandar - which is a proud partner to many key brands in the market.

PW: Lastly, can you share a lesser-known fact about Pune that might surprise our readers?
RM: Pune is home to some of India's oldest and most respected educational establishments, such as the Savitribai Phule Pune University (formerly known as the University of Pune), Fergusson College, the College of Engineering Pune Technological University (COEP) and diploma and degree colleges in printing technology. These institutions have produced many prominent scholars, scientists, and leaders who have made significant contributions to various fields globally. Aligning with its name, Oxford of the East, Pune has developed into a major hub for book publishing, self-publishing, book printing and book-on-demand services.

PW: Any packaging connection?
RM: The city is a hub for mechanical, electrical, and software engineering innovations, where cutting-edge research and development in robotics, automation, and advanced manufacturing techniques are showcased. Leading manufacturers like Bobst, Pratham Technologies, and our panellists for Make in India Superstars @ Drupa. Pune’s strategic location, excellent infrastructure, and availability of skill and talent foster a thriving ecosystem for leading companies like Tetra Pak, Parkson Packaging, BHS Corrugators, WestRock, and many more.

PW: And any print connection?
RM: A lesser-known fact about Pune that might surprise you is its significant role as a contributor to the growth of the print industry in India, one such example is, that Pune is the birthplace of the iconic “Kesari” newspaper, established in 1881 by the legendary freedom fighter Bal Gangadhar Tilak. Kesari played a pivotal role in India’s struggle for independence and continues to be a symbol of the city’s rich cultural and journalistic heritage. Another one is the presence of The Poona Press Owners Association (PPOA), established in 1919, fostering a collaborative environment for printing professionals and having recognition as founder members in the formation of the All India Federation of Master Printers (AIFMP). Taking it forward, we should not miss out on the historical significance of Chitrashala Press, a pioneer in lithographic printing in India. Chitrashala Press was founded by Shivram Mahadev Paranjape in 1878.

PW: What message would you like to share with printers and converters across India?
RM: The print industry is resilient and continues to thrive post-Covid-19, especially in domains like book publishing and packaging. Staying updated with technological advancements and being judicious with investments is crucial, given the rapid pace of technological evolution. Keep up your spirits and be a proud printer.

Navin Kotadia — Rajkot Printing and Packaging Association

PrintWeek (PW): Congratulations on your recent election as the president of RPPA.
Navin Kotadia (NK): Thank you. It's been three months since the new core team took over. We’ve entered the second term of RPPA, and we have a very strong core team of printers working effectively.

PW: What’s the latest update on your association?
NK: Our association, comprising over 106 members from diverse sectors like trading, printing, packaging, and design, is focused on addressing community and market changes. Our members work for direct clients as well as take job work from designers who design print material and packaging.

There is also another association in Rajkot, the Commercial Printers Association, with offset printers, screen printers, freelancers, and designers as members. It’s an association which began in 2007 but isn’t as active as an association should be.

RPPA was established in 2017 with an agenda to work cohesively, bringing technological trends and market developments in the printing arena to the knowledge of the association members as well as sales-driven conversations.

PW: What are your current focus areas for improving the community?
NK: We are working on supporting lower-level businesses, particularly second-generation printers, by fostering face-to-face interactions and awareness. It's crucial to enhance market reputation and value through effective packaging.

Additionally, most of our members are second-generation businessmen, hence use a WhatsApp group to share technical information through PDFs and videos.

We also have many designers, especially freelancers working in B2B, whose talents we want to leverage. While our printer members deliver quality, our current focus is on driving innovation.

In November-December 2024, we are planning to host a Conference, which will have knowledge sessions as well as networking opportunities.

PW: What are your thoughts on partnerships between printers?
NK: Partnerships between printers are crucial, as combining expertise from different fields can lead to successful collaborations. We aim to expand infrastructure, manpower, and technology through these partnerships.

RPPA encourages a collaborative business concept, which I think is key to reducing competition and enhancing innovation, provided we maintain a better structure and mindset, even if the platforms differ.

To give you an example: We have a membership of 106. If individually we compete, each one will have 105 competitors. If three members with different expertise and strengths collaborate, the competition is down to just 30.

PW: How do you manage price pressure?
NK: Price pressure varies across different categories and client requirements. The reason is that each print service provider has his unique strengths, it may be the ability to print quickly, or use its post-press strength to create an innovative box. The question of price pressure does not arise.

Industries such as hardware foundries, kitchenware, and automobiles are driving its economy. There is neighbouring Jetpur, which is another industrial hub and of course, Morbi, which is 60kms away from Rajkot. All these industries are driving the demand for print and packaging.

So, with a growing market, there's space for everyone, so we adapt to maintain value while managing price challenges.

PW: What’s Rajkot print service provider USP?
NK: Our USP is centred on packaging, but we also handle a significant amount of commercial work.

PW: Did your association members travel to Drupa 2024?
NK: Yes, our association partnered with a travel and tour company and flew 22 members to Drupa.

PW: What feedback did you receive from Drupa?
NK: The feedback was positive, with many discussions focused on digitalisation and gravure flexibles.

PW: What is the general trend you observed at Drupa?
NK: We observed that the print and packaging market is booming, especially with a significant rise in demand for labels. This underscores the growing need for automation/digitalisation, flexo, and labelling solutions.

PW: What is the distribution of printer sizes in Rajkot?
NK: Rajkot is a hub for the print and packaging industry, boasting around 200 firms. The top 10 companies have a turnover ranging from Rs 25- to Rs 30-crore, positioning them as large print and converting firms with over two multi-colour presses. Additionally, approximately 40 firms with turnovers between Rs 5- and Rs 10 crore are equipped with one or more four-colour presses.

Furthermore, there's a cluster of about 50 small print and converting firms with either two-colour or single-colour presses and a turnover of under Rs 3 to Rs 5 crore. Moreover, around 100 screen printers and designers have turnovers in the Rs 1-crore range. The designers depend on the print-packaging converters and screen printers to actualize their designs.

PW: How many four-colour printers are there in Rajkot?
NK: There are approximately 400 four-colour printers in Rajkot. Around 10% are newly established, while the rest are older, established ones.

PW: What is Rajkot known for that others might not be aware of?
NK: Gujarat is renowned for its high-quality micro embossing jobs, which is a unique strength in the region.

PW: What are the upcoming targets for your association?
NK: Our targets include increasing membership with a focus on quality, advancing technology and professionalism, and shifting traditional mindsets to more professional approaches. We also plan to set up a system with scheduled meetings on specific topics and trending conversations.

President Speak: Raanu Bisht

PrintWeek Team — Tue, 20 Aug 2024 09:37:00

What is the first thing on your agenda?
My top priority is to educate and train team members on the Government eMarketplace (GEM). Many in the printing industry, particularly those working with government contracts, struggle because all obligations must be met through GEM. Enhancing technical literacy is essential for effective participation in GEM. Also, the government policies at the state level need to be studied and if any intervention is required, then it has to be addressed.

What is your plan for the next 12 months?
Our goal is to join the All India Federation of Master Printers (AIFMP). Our next step involves connecting with more printers and publishers in Uttarakhand to establish a robust organisation. We aim to motivate our members to engage in print competitions, organise interactive sessions, and arrange meetings with GST officials to address any concerns.

We are aware of Zircon but can you give us a sense of the print and packaging industry in Dehradun?
We have more than 100 offset printers in Dehradun engaged in commercial printing and job work. Some are engaged in publishing also. But there are very few printers for packaging. To name a few, Alpine Industries, Shakumbhari Packaging, and Anil Enterprises. Dehradun has huge potential for the packaging industry, thanks to its geography and its development. Also, the government facilitates investors and entrepreneurs with its enduring policies.

How was Dehradun impacted by the recent landslides and floods?
Our city has been minimally affected by the recent landslides and floods. However, is has impacted the peripheral areas along the riverbanks. The most significant impact has been felt in the mountain region.

There is huge uncertainty about the cost of raw materials. How are your members and their factories coping?
Dealing with increased raw material costs and uncertainty in the printing industry requires a strategic approach. We explore alternative vendors for raw materials to negotiate better prices. Trying to optimise material usage by implementing efficient printing processes and reducing waste. The members are passing on increased costs to customers through price adjustments. Some are also maintaining optimal inventory levels to avoid overstocking and renegotiating contracts with suppliers. We all are eyeing and monitoring market trends to adjust strategies accordingly. All of us have felt the significant effects of last year’s price increases, particularly in paper prices. As a result, many of us are being extra careful when providing quotes.

What kind of conversations are you having with your customers?
At Samaya Sakshaya, our conversations with customers are focused on understanding and realising their unique visions through detailed discussions that capture the essence of their ideas and goals. We emphasise fair trade practices, transparent and fair pricing, and responsible sourcing to ensure ethical operations and environmental sustainability.

By delving into technical aspects like paper types, printing techniques, and design elements, we align every detail with the client’s expectations, offering expert advice to enhance the final product. Our collaborative approach fosters strong partnerships, keeping clients informed at every stage and building lasting relationships based on trust, quality, and a shared commitment to excellence.

Any steps taken by the Devbhoomi Printers and Publishers Association, Dehradun with the government?
The Devbhoomi Printers and Publishers Association has had a meeting with the GST Council regarding the issues of taxation percentage and to keep the association informed about any changes in the policy regarding GST. The team met then chief minister Trivendra Singh Rawat regarding the cancellation of calendar and diary printing in the Uttarakhand state government department.

We have had a conference where the higher officials from the industries department enlightened the members regarding the MSME and other industrial policies. It allowed looking into the existing schemes, policies, and initiatives supporting our industry. Our association is trying to prepare a strong case with facts and data about the printing and packaging industry’s potential, challenges and growth opportunities in our state to have them back us.

One lesson you have learnt from the past 50 months?
One valuable lesson I have learned over the past 50 months is the importance of adaptive leadership and effective communication. Navigating various challenges, especially during unpredictable times, has reinforced the need to stay flexible and open-minded as a leader. Embracing change and being willing to pivot strategies when necessary is crucial for maintaining the resilience and growth of an organisation. Additionally, fostering transparent and empathetic communication within the team has proven essential for building trust, encouraging collaboration, and ensuring everyone is aligned with our vision and goals. These experiences have underscored the significance of leading
with agility and compassion to drive sustained success.

As president of the Devbhoomi Printers and Publishers Association, Dehradun, what is your message to the fraternity for 2024-25?
My message to the fraternity for 2024-25 is one of unity, innovation, and resilience. In the face of evolving industry dynamics, it is crucial we embrace new technologies and sustainable practices to stay competitive and environmentally responsible. Collaboration and knowledge-sharing among members will be key to overcoming challenges and seizing opportunities. Let’s continue to support each other, uphold the highest standards of quality and ethics, and work collectively towards advancing our craft. Together, we can inspire positive change and ensure the continued growth and success of our industry.

Katsuhisa Asari: Our strong market presence in India reflects our commitment

Rahul Kumar — Wed, 14 Aug 2024 14:18:00

Rahul Kumar (RK): At Drupa this year, Konica Minolta had the seventh-largest booth and at least 20 product premiers. The focus was on end-to-end solutions. How did the market respond to your offers?

Katsuhisa Asari (KA): Konica Minolta had a substantial presence at Drupa, highlighted by a vast booth and numerous product launches, which generated immense excitement and interest. Our focus on end-to-end solutions resonated strongly with the market. The ability to showcase over 30 hardware and 25 software products, including inline finishing options for production presses, demonstrated our comprehensive approach to addressing customer needs. We looked upon the opportunity to present end-to-end solutions to the customers from pre-press, press to post-press solutions, including embellishment. The customers were excited to see the solutions and as a one-stop OEM to their needs in the production environment with automation.

RK: Konica Minolta’s approach appears to be a one-stop solution provider, offering, “the print room of the future.” Could you explain this approach?

KA: Konica Minolta aims to revolutionise the printing industry by transitioning from analogue to digital processes. We offer a holistic solution, encompassing commercial, label, packaging, and industrial printing. Our extensive product range, coupled with pre- and post-printing solutions, positions us as a one-stop shop, optimising efficiency and minimising environmental impact.

RK: What’s new at Konica Minolta? At Drupa, there were talks about programmatic printing with AI and Industry 5.0 focusing on sustainability…

KA: Konica Minolta is at the forefront of industry transformation. Our Drupa showcase featured groundbreaking technologies, including AI-driven programmatic printing and sustainability-focused Industry 5.0 initiatives. Ex Kansei, a predictive software utilising eye-tracking data, offers invaluable insights into consumer behaviour. By understanding attention, impression, and positioning, businesses can make data-driven decisions to optimise marketing materials. It also includes the first-of-its-kind B1 size digital inkjet press Alphajet with spot UV and digital Foil. We also launched our next generation B2 size Digital Press KM 60000 with printing. Among solutions, we also demonstrated KM strength in inkjet head technologies and colour management.

RK: Today, the line between a commercial printer and a converter is getting blurred, with most commercial printing venturing into packaging as well. Under these circumstances, who are your ideal customers? What are your approaches to reaching out to them?

KA: The printers and packaging converters are now feeling the need to expand and offer more solutions to the changing requirements of the customers, primarily because of the number of SKUs and personalisation/customisation options. Konica Minolta targets businesses entering the cosmetics, FMCG, healthcare, and pharmaceutical sectors, which require short-run, high-quality packaging. Our comprehensive solutions, including smart and sustainable packaging options, perfectly align with their needs. By educating customers about packaging opportunities, we expand their business horizons and create new growth avenues.

The Konica Minolta India team at Drupa 2024

RK: How is your label press business doing? Is anything new on this front?

KA: Our label press business is thriving due to increased demand from new market entrants. The ease of use of digital printing is encouraging more companies to get into digital label printing, a segment which is fast growing. The AccurioLabel 400, with its white ink capability, caters to a broader range of industries. We are optimistic about continued growth in this segment.

RK: Inkjet is the talk of the town. You have done a lot of work on the inkject technology. What’s the latest?

KA: Inkjet technology is rapidly gaining prominence, and Konica Minolta is at the forefront of this revolution. Our latest inkjet innovation, the AccurioJet 60000, made its debut at Drupa. This high-speed, UV inkjet press boasts impressive speeds of 6,000 sheets per hour while delivering exceptional image quality. Building upon the success of our AccurioJet KM-1e series, the AccurioJet 60000 offers enhanced features and usability, providing customers with maximum value and efficiency. We also demonstrated the new Alphajet B1 size inkjet press with UV and foil and the inkjet solutions from MGI for spot UV and digital foil.

RK: Recently, we read that Fujifilm Business Innovation and Konica Minolta are planning to form a strategic alliance involving production printing devices, multifunction and office printers. Please share some details.

KA: We have signed a memorandum of understanding to begin a feasibility study for a strategic alliance in the multifunction printer (MFP), office printer and production printer segments.

RK: How is Konica Minolta doing in India? Could you please share the latest installation numbers? What according to you is the most popular KM product in India?

KA: Konica Minolta holds a dominant position in India's digital production printing market, boasting a market share exceeding 50%. Our comprehensive product portfolio caters to a diverse clientele, ensuring that businesses of all sizes can find tailored solutions to optimize their operations. This strong market presence is a testament to our commitment to delivering exceptional products and services to our Indian customers. Currently, Konica Minolta in India has the widest portfolio in the industry, which empowers customers to choose based on their needs and market demands. We provide solutions to all the major segments in the printing business including commercial printers, packaging printers, print shops, label converters, service bureaus, book printers, etc.

RK: In the last two years, Konica Minolta India conducted several roadshows to reach out to customers in tier-2, and tier-3 cities. How successful was the initiative?

KA: Being a market leader in digital production printing in India for more than a decade, we take this opportunity to expand the market to smaller cities and create more opportunities for printers to embrace the benefits of digital printing. The PrintXpress flagship roadshows have been instrumental in expanding Konica Minolta's footprint across India. By reaching previously untapped markets in tier-2 and tier-3 cities, we have identified significant growth potential. Moreover, our initiative to empower local entrepreneurs with the right tools for charting a lucrative career in the printing industry has induced much-needed impetus in the overall development of the printing industry in these regions.

RK: What’s next in your plan to capture the digital printing market in India?

KA: Konica Minolta is dedicated to the long-term success of our Indian customers. Our future plans involve the development of cutting-edge, sustainable solutions that address the evolving needs of the market. By combining innovation with a deep understanding of customer requirements, we aim to drive efficiency, profitability, and growth for businesses of all sizes.

Katsuhisa Asari: In Brief

Your proudest achievement in the Drupa year?

The successful launch of the AccurioJet 60000 stands as our proudest moment. Gauging the overwhelmingly positive response from customers and industry experts, we are proud our innovations are so well-received.

Who is a typical KM customer?

Our ideal customer is a forward-thinking business seeking to create and optimise their printing business. Whether it's a commercial printer, packaging converter, or in-house print department, we offer tailored solutions to enhance efficiency, productivity, and output quality.

Which is your popular press model?

The KM-1e remains a highly sought-after press due to its exceptional reliability, versatility, and image quality. It has consistently delivered outstanding performance for our customers across various applications, making it a cornerstone of our product line.

How much of your business comes from repeat customers?

Our strong base of repeat customers is a testament to our commitment to customer satisfaction and long-term partnerships. Their continued trust in Konica Minolta is a driving force behind our success and reinforces our position as a reliable industry leader.

What’s your team’s favourite print success story among small business units in India?

It would not be right to mention one as a favourite success story because as I have already mentioned for us it is about the uniqueness of every customer and we value that as for us every installation is equally important because it is not only a machine purchase it is a long term association which is built between the customer and the brand, machine installation is just a beginning of that bond and relationship.

Urvashi Butalia and the journey of a small press

PrintWeek Team — Thu, 01 Aug 2024 12:11:00

Zubaan is an independent publishing house, with a strong academic and general list. It was set up in 2003 as an imprint of India’s first feminist publishing house Kali for Women, and continues to publish books on, for and by women in South Asia.

Butalia began by tracing her journey from the 80s, reminiscing how print technology at the time was essentially transitioning from letterpress printing, hot metal and cold metal typesetting, and how the publishing house has covered an entire arc from phototypesetting to offset printing and computers, a voyage through technologies.

“My journey began with a printing press. I instantly fell in love with the idea of something coming alive under the press, and that something being something for the brain,” she said.

She spoke of what she calls the most important book of her press, called Shareer ki Jankaari, which means Knowledge of the Body. The story of the book is a touching one. A group of village women, part of the women’s development programme of Rajasthani women in the 1980s conducted health workshops and created the book. The book was about menstruation, sex and bodily autonomy. When the women came to Zubaan, Butalia and her team were thrilled, especially because it was village women who had created it.

The women had non-negotiable conditions; firstly that the book could never be sold to a village woman at a profit, and secondly the names of all 75 authors had to be printed on the cover. The publishing house agreed and had the opportunity to hear all the wonderful lore about how the book came to be created.

The women stated that initially, the book had included diagrams of the naked man and the naked woman, side by side. However, when they attempted to test it on other villagers, they were scoffed at, stating that ordinarily, one would never see a naked person in the village. The authors then came up with the ingenious solution of having a woman completely covered from head to toe, but when you lifted little flaps up, you could see her entirety, her breasts, and when you put the flap down, she was still modest.

“The book, Shareer ki Jaankaari, is what prompted Zubaan to start thinking about the margins — marginalised regions, languages, and religions and we start to build our books around those things,” said Butalia. “We found ourselves looking at books by Dalit writers and we started to publish them slowly.”

Today Zubaan boasts of a collection written by Kashmiri women, Dalits, Muslims and those from the North-East. Another prominent book is Do You Remember Kunan Poshpora? about the mass rape in Kashmir in 1991.

“We try to live our feminism,” said Butalia. “When we put up job announcements, we often do it for those of reserved castes/ spaces. It’s important for us not to be people of privilege.” Zubaan is now a workforce sourced from all over India, a matter of which the team is proud.

The future of Zubaan however, is ambiguous. The organisation is a founder-led one and Butalia herself is 75 years old. That the organisation lacks funds provides no ray of brightness either. The options seem stark: selling the company or shutting down.

Zubaan’s dream, however, is to digitise everything; create an online library of all the books that they have published and then offer that to libraries across the world, to preserve their legacy.

As Butalia said, “It’s all about the importance of hearing voices that we have ceased to hear.” After all, there are so many Zubaans that continue to be unheard.

Umesh Nema: Offset is preferred for its image quality and huge volumes

Abhay Avadhani — Mon, 29 Jul 2024 13:20:00

What is the trickiest colour that you have had to print?
The trickiest colours to print accurately are purple and grey.

What is the quality you seek when you hire?
Technical skills and knowledge, printing expertise, problem-solving abilities, troubleshooting, and interpersonal skills.

What is your favourite print joke?
Why did a print job go to therapy? It had too many issues.

Describe your day in two sentences.
Quite productive, filled with engaging conversations and insightful tasks.

Which process do you prefer?
Offset printing is preferred for its superior image quality, consistency, and efficiency in producing large volumes at a lower cost per unit.

What is the greatest strength of your printing firm?
The commitment to quality and innovation.

Which job or project made you the happiest?
Securing the contract for a battery label job for a multinational company.

One job you wish you had printed?
ITC Dark Fantasy biscuits packaging with the UV mat-pet technology.

Which living print person do you admire the most?
My father, JP Nema.

Which print technology, according to you, is the future?
Digital print technology.

A technology that is passé for the 21st-century press?
Traditional offset printing, especially for short-run jobs.

Your favourite print conference?
Romancing Print, organised by the All India Federation of Master Printers in tier-three towns.

The mystery of the warped book: Causes, effects, and solutions

Suresh Nair — Wed, 17 Jul 2024 09:31:00

Have you ever encountered this issue as a book printer? You print and bind a set of hardcover books that pass quality control perfectly, only for the customer to call and inform you that they received a shipment of warped books. This isn't the case of a haunted library – it's a common printing mystery called book warping. But fear not, fellow book lovers and print professionals, I will try to crack the code and make your books look sharp.

The Warping Woe – A detective's introduction: Just like a detective examining a crime scene, we need to understand the warping phenomenon. Book warping refers to the distortion of a hardcover book, where paperboard covers bend, curl, or buckle. It occurs when the cover lifts away from the open side of the book. This can be seen along the spine or bulge outward, disrupting the book’s aesthetics and durability. This affects the book's aesthetics, can hinder readability, and causes damage over time.

Unveiling the Culprits – what causes book warping?

Moisture mischief: The culprit most often behind warping is moisture imbalance. Dispersion adhesives (water-based) used for binding can release moisture, which the book board absorbs unevenly, causing warping. Uneven distribution of moisture during the binding process or fluctuations in humidity levels post-production can cause paper fibres/paperboards to expand or contract unevenly, leading to warping.
Material compatibility: Using incompatible materials for the cover, pages, or adhesive can lead to warping as these components interact and age differently.
Uneven glue application: Inconsistent adhesive application during casing-in (attaching the cover) can also lead to uneven warping.
Board blunder: The quality and grain direction of the board itself play a role. Ideally, the grain should run parallel to the spine to minimise warping.
Temperature trouble: Extreme heat or cold during storage can cause paper fibres to contract or expand unevenly, contributing to warping.
Acidic content: Recycled paper or board with high acidity levels can become brittle over time, increasing the likelihood of warping and deterioration.

Introducing the end sheet and casing-in process:
Before diving deeper, let's meet two key players in the bookbinding process:

Endsheets: These are blank pieces of paper attached to a book block's first and last pages, providing strength to the hinge and holding the book block together.
Casing-In: This is the process of attaching the cover (made during case-making) to the book block using glue.

Endsheets and casing-in – Potential warping culprits
Improper glue application during casing-in can contribute to warping. The glue used often has a higher water content than glues used in case-making. If this moisture isn't evenly distributed or properly dried, it can cause the bookboard to warp.

Tunnelling: The Inward Warp
I've discussed warping and the outward bending of the cover. But there's another suspect: tunnelling. Tunneling occurs when the cover bends inwards, creating a tunnel-like shape. While warping and tunnelling are caused by moisture imbalance, the location of the bend helps identify the source.

Identifying the moisture source – A visual clue: By examining the location of the warping, you can get clues about the moisture source.

Warping on the open side (where the pages meet the cover): This suggests moisture from the casing-in process, likely due to uneven glue application or insufficient drying.

Warping on the closed side (spine area): This points towards the case-making process. The glue used here might have a higher moisture content that wasn't properly managed.

Grain direction and moisture – A warping recipe for disaster: Grain direction refers to the natural fibre direction within the board material. When the grain runs perpendicular to the spine, it allows moisture to travel more easily, leading to more pronounced warping. Ideally, the board should have the grain running parallel to the spine for optimal stability.

Case-making vs. casing-in – Understanding the glue game:

Case-making: This process creates an empty cover using cardboard and various materials. Glues used here, like jelly glue or animal glue, typically have a lower water content. Utilising specialised machines, the case — a cover with boards — is formed using adhesives that can affect moisture content. The type and application of adhesives set the foundation for potential warping issues." Warping after the case-making process or tunnelling can be detected by the operator by visual inspection before you begin the casing-in process. However, 90% of the warping happens after casing-in, and this may manifest after the book is shipped.

Casing-in: This step attaches the pre-made cover to the book block. Water-based adhesives with a higher water content are commonly used for this process. The higher water content ensures strong adhesion, but it can lead to warping if not managed properly. This process involves careful handling to prevent uneven moisture distribution that leads to warping and tunnelling.

Effects of book warping: The effects of book warping extend beyond aesthetics:

Aesthetics: Warped pages and covers diminish the book's overall look and feel, impacting its visual appeal.

Durability: Severely warped pages may crack or tear, compromising the book’s structural integrity and readability.

Reader experience: Warping can make it difficult to open and read the book comfortably, affecting user experience.

Cracking the case – Solutions to prevent book warping
With the suspects identified, here's how to prevent book warping and ensure pristine book quality. The team at Bindwel emphasises proactive measures to prevent and mitigate book warping:

Adhesive selection: It is crucial to choose the right adhesive based on board compatibility. Conducting adhesive tests ensures optimal performance and minimises the risk of warping. Testing before full production is essential.

Moisture management: Using high-solid content water-based adhesives reduces moisture release during binding, helping maintain paper integrity.

Grain direction matters: Aligning the grain direction of the board parallel to the spine reduces the risk of warping, but perpendicular to the spine (cross grain) will lift the bend or curl the corners of the open side.

Climate control: Maintaining stable temperature and humidity levels in production and storage environments prevents moisture-related warping.

Quality control is key: Using high-quality materials throughout the post-press process minimises warping risks. Implementing best practices in board preparation and binding techniques ensures consistency and durability in book production.

Bindwel’s role in combatting book warping
As an industry leader in printing solutions, Bindwel is committed to empowering printers with innovative technologies and expert guidance. Our approach addresses common challenges like book warping, ensuring your printing projects achieve exceptional quality and durability.

Bindwel offers a range of high-quality bookbinding materials, including adhesives specifically formulated to prevent warping.

Don't let warped books become a part of your printing story.

HP’s bullish case for large-format segment - The Noel DCunha Sunday Column

Noel D'Cunha — Sun, 14 Jul 2024 06:00:00

Noel D’Cunha (NMD): What exactly is your role at HP?
Oscar Vidal (OV): Everything that has to do with large-format products. We basically design the product roadmap for all large-format printers, whether for architects, engineers, or print jobs all the way to very high-end graphic producers. We have a global responsibility. So we've had to understand all the different market needs across the globe and try to come up with nice solutions to help our customers become more successful national contenders globally.

NMD: What are the trends in large-format printing? How are the applications evolving?
OV: The latest news is that print volumes have exceeded pre-Covid-19 levels on a global scale. We track the market in terms of printed material in dollars and square meters yearly. Currently, the volume of production in the wide-format segment is higher than that of 2018, indicating a growing and active market. According to our internal projections, we anticipate a compound growth of around 5 to 6% in the wide-format segment. Certain applications, especially those focused on aesthetics, are experiencing faster growth, such as wallpaper printing, digital decoration, floor graphics, and more. High-value applications like these are expected to drive significant growth. Our latex products are well-suited to meet the quality demands of this market. Additionally, there is an increasing demand for backlit textiles, particularly in commercial and home use, for enhancing office and home decor.

Following Covid-19, companies are investing in redecorating their offices to motivate employees to return, and digital printing is playing a key role in this. Furthermore, traditional applications like vehicle graphics continue to be active and are expected to grow. The use of printed output combined with digital screens is proving effective and impactful.

NMD: What is the size of the wide-format industry – worldwide and India?
OV: In 2023, 253,193 units were sold worldwide. Of these, 4% (9,358 units) were sold in India.

NMD: Yeah, so getting back to your role, you have a global responsibility. As you oversee various applications and markets, including those in developing stages, and since you have a global perspective, you also have insights about India. Could you elaborate on how India fits into the global perspective and the opportunities it presents?
OV: India is definitely a priority country for us. It has a lot of growth potential and a rapidly growing economy. Our focus in India is important and will continue to help the market develop. It's crucial to educate print shops about the potential to produce wallpaper digitally, as many are used to traditional methods like offset or silkscreen. India's wallpaper market is large but still very traditional, offering a big opportunity for us to introduce digital and personalized printing. We are already working in this area and see a lot of potential for decor opportunities in India.

NMD: What is your opinion on the current status of thermoforming applications? We understand that it is experiencing a growth rate of approximately five to 7%.
OV: We have some fascinating technologies for thermoforming. One benefit of our latex materials is the flexibility of the latex inks we use, making them ideal for thermoforming. Unlike other materials, our latex inks conform well during thermoforming and do not crack. However, thermoforming is a specialized process that requires expertise and specific machinery, so it's not commonly found in small shops. We are actively involved in the thermoforming industry; for example, we have several successful customers in the United States using our latex hybrid devices to print directly on plastic, which is then used in the thermoforming process. While we have not yet penetrated the market in India, we see potential due to the compatibility of our technology. However, we also need to prioritise various opportunities to ensure success.

NMD: It’s an interesting market, so you may have challenges from your competitors...
OV: I'd rather not discuss others, but we're performing exceptionally well. Our properties are running as we expected, and our customers tell us that when they try this with other technologies, they experience issues like cracking problems or poor ink conformation. However, some other vendors have also formed a dedicated team for this application, so it's definitely an interesting market.

NMD: Are you telling me that there are separate inks for thermoforming applications...
OV: For other technologies, you'd need different inks for different uses. But in our case, we use the same ink for posters, curtains, and even for wrapping cars. That's one of the great things about it – the versatility. You don't need to buy multiple machines and equipment for different purposes. With our latex technology, one piece of equipment allows you to handle various tasks. This is especially helpful for growing markets where capital is limited. I personally find this approach appealing as it allows for progressive investments. This makes a lot of business sense for someone who doesn't have large amounts of initial capital. If the business grows, you can gradually expand, which is a very practical and appealing approach.

NMD: Earlier, there were only two or three types of substrates available. Now, there is a wide variety of substrates, ranging from low quality with several types to better quality options. This variety may pose a challenge for customers.
OV: We ensure that we thoroughly test and design all printing capabilities and make necessary adjustments to ensure the quality of our materials. We aim to have a strong connection with countries on a global scale to understand the top materials used in each country. It's important to address any specific local concerns and issues that may arise. We have developed special configurations to ensure compatibility with all available materials. Anticipating the needs of the market, we test all these aspects before launching a product.

NMD: Another market where a lot of digital is penetrating or making a mark is the textile sector. There are two types of applications: apparel and clothing produced in bulk, which are produced on behemoth textile printers, and signage on textiles. You don't have a presence in the large digital printing presses for such a market.
OV: Our main focus in the textile industry is on signage rather than apparel. We are not primarily focused on designing printers for apparel production. Instead, we concentrate on textiles for signage such as flags, banners, and light boxes, all essential for effective communication. While we do have some involvement in apparel, our main emphasis is on soft signage, which is a rapidly growing sector. Many people prefer textile banners because they are lightweight and cost-effective to ship and handle. Our Stitchline and our brand of inks, HP Stich, have been successful in the sub-signage segment.

NMD: In this sub-signage segment, is it Latex or dye sublimation?
OV: The choice between dye sublimation and latex printing depends on the production volume and the specific applications you want to focus on. If you produce a significant amount of volume, dye sublimation can be very efficient because it is dedicated to the task. However, if you only print one banner a week, it may not justify having both a latex device and a dye-sub device. Consider your volume profile and how often you produce these applications. Dye-sublimation has advantages for textile work, offering a wider range of materials. It depends on how you want to approach a certain application. If you focus on promotional or fashion items due to high volume, dye-sublimation is the answer. However, you can use latex printing if your customers only request an occasional flag. If your volume increases and you want a dedicated machine, then a dedicated dye-sublimation device may become a consideration.

NMD: So the key is profitability?
OV: Its flexibility and profitability. Dye-subs can definitely print on more textiles than Latex. If you want to print on five different types of textiles, dye-subs will do a better job. But then, if you want to print on five textiles, it means you have a lot of volume.

NMD: Which HP printers can produce dye-sub applications?
OV: We have two machines, the S1000, a 3.2-metre super-wide machine and S500, a 64-inches machine. Both of them can be used to produce dye- sublimation applications.

NMD: The other topics are sustainability and tackling wastage.
OV: We take sustainability very seriously. It is one of the three strategic pillars of our business. Our business is built on three pillars: stunning quality, streamline efficiency, and sustainability. Our aim is to ensure high-quality and environmentally friendly products. For instance, our inks are water-based and do not contain harmful chemicals. We also encourage our customers to use recyclable materials with our inks to make the final products more sustainable. We are focused on reducing the environmental impact of our products and helping our customers become more efficient in their production processes.

Additionally, we are working on developing products that can be upgraded over time to minimize waste. Our commitment to sustainability extends from our ink to our hardware design and the materials used in our factories. We take sustainability very seriously and consider it from a 360-degree perspective.

NMD: We know that HP collects its cartridges in the packaging segment. Do you have a similar programme for your wide-format segment?
OV: We collect the cartridges and recycle them. So we combine all these cartridges into recycled plastics for another purpose. Yes, we recycle our own cartridges as long as customers send them back to HP.

NMD: What about the printed material?
OV: We do not accept printed materials. They are often produced locally, and this presents a challenge for us. We only use our own cartridges because we are familiar with their manufacturing process and know how to recycle them. If someone wants to dispose of printed materials, we consider it a local issue because we aren't sure how they were produced. However, if we know any organisations that can collect this type of waste, we connect them with our customers.

NMD: Printheads: Are they the same as the ones used for the HP PageWide presses? How easy are they to maintain?
OV: No, they're not the same for the textile printer. They have a different architecture. We made some small changes inside, so the ink flows differently.

As for maintenance, it's much easier than the PageWide printhead because of our simpler machine. Therefore, the replacement of the printhead is very straightforward, taking only about three minutes. The printer then recalibrates itself automatically.

NMD: When it comes to the market traction that HP is gaining, which market do you see as crucial for HP as a press manufacturer?
OV: We have several growth opportunities globally. It's hard to pinpoint just one country, but I would say India is among the top five countries with a lot of potential for us. There is significant construction activity in India, and we also sell plotters to print drawings. From a building standpoint, the more buildings and offices are being constructed, the more opportunities there are for digital print to decorate these spaces. India definitely stands out as a big growth market for us, in terms of volume. However, we are closely monitoring other pockets of potential growth as well. Established markets like Western Europe, the US, North America, and Latin America also hold great potential for us. So, we are balancing our focus globally, with India being one of our top priorities.

The Arvind Sekhar masterclass: The Theory of Knowledge - The Noel DCunha Sunday Column

Anhata Rooprai — Sun, 16 Jun 2024 06:00:00

Using an interactive poll with the audience, Arvind Sekhar, the director of Sai Packaging, established that India ranks very low in terms of profitability compared to any other region in the world. He said, “In the packaging industry, the print industry in countries like Indonesia, Pakistan, Sri Lanka, and Bangladesh sees a far higher return on capital as compared to India. You would find them upgrading their machines much more frequently than the print fraternity in India.”

He said that this is the reality within which Indian print entrepreneurs must find ways to survive. He went on to highlight the various concerns of the printing and packaging industry members — economies of scale, pricing, power costs, logistical expenses, low profitability, high working hours, expensive machinery, and high foreign exchange rates.

Sekhar highlighted how, despite these concerns, industry leaders are expected to forefront sustainability initiatives, anti-counterfeiting, and innovation. He asked the audience, “Where do you get the human capital to think of these ideas?”

Should the onus of ideation be solely on industry leaders, many of whom are part of this industry because it is all they know? By popular demand, Sekhar used the occasion to speak about the viability of this industry for the next generation in family enterprises.

His first question was, “Why does your company exist in the market versus competition?” He gave the example of Rajiv Bajaj, the CEO of Bajaj Auto, whom he dubbed his industry guru, who had said, “It’s not what you do, it’s what your competition allows you to do.” Therefore, it becomes important for a company to articulate how it is different from the competition.

Sekhar said that a company can exist and survive for three reasons. “One, it is far more innovative than the others in the market. Two, it is the most inexpensive producer combined with economies of scale and services available at multiple locations. Three, it boasts supply chain excellence, whether with quality assurance or high on-time in-full (OTIF) scores across the board,” he said.

According to Sekhar, identifying and understanding a company’s strengths is the first step. Quoting Azim Premji, he said, “We spend far too much time worrying about our weaknesses. Forget about it. Focus on your strength, and build that strength.” Sekhar said that this identification is the first step in equipping your company for the next generation.

He emphasised that a company must decide its focus. “It cannot specialise in multiple things.” He gave the example of Vijay Mallya, who tried to run an aviation company and a beer company at the same time. According to Sekhar, that was his undoing.

Sekhar also said that it is a big risk to confuse cause and effect. He said that unless we find a solution to existing problems, expecting the next generation to want to join the enterprise is unreasonable. “The conversations and environments in each company will be different, based entirely on what its focus is.”

Sekhar said that whatever a company’s specialisation may be, it is a people business at the end of the day. Attitude is what matters most. He said, “When I hire people, I am looking at hiring somebody to serve that specialisation better. Suppose I hire someone extremely creative in design. In that case, they may feel like a fish out of water because they are unfamiliar with the regular conversation that’s happening inside the organisation that has taken its focus on supply chain excellence. So, the culture in your organisation will be different based on the pillar you have chosen to focus on.”

An audience member pointed out that the people in the organisation should support the management in achieving the company's aim. Sekhar responded by referring to W Edwards Deming. Sekhar said that Deming inverts the organisational chart and puts the onus on the management to ask themselves what they are doing to earn the trust of their people. While quoting Deming, Sekhar said, “85% of the problems in a company are caused by the management, and not by the lower-level employees.”

Therefore, Sekhar said that management has to make an effort to “fix themselves.” After this, the company should consider the next generation.

Sekhar lauded the effort required to start from scratch and stated, “Don’t let the magnitude of this change fool you into thinking that you have done better than the previous generation. So, this requires an honest assessment of the ambition of the next generation. We need to probe this deeply.”

He said that a company can shine in a tough industry, but if it has not answered these questions, it will face challenges and dissatisfaction. That is why, according to Sekhar, it is helpful in a family business to have an external, trustworthy member who will facilitate these difficult conversations.

Sekhar gave the example of Autajon Packaging, whose CEO and chairman is Gérard Autajon. According to Sekhar, the company has only grown through acquisitions. “Autajon’s children are not in the business. The company's strength has been letting the existing promoters continue, even after the acquisition,” he said.

Another question was posed to Sekhar: “How do you convince the previous generation to stay updated on current trends and technology?” To this, he said, “When I face a problem like this, I try to articulate what is bringing us success today and what we are trying to build using this technology. Once the answer to these questions is found, the usage of these technologies will fall into place on its own.”

Next, Sekhar spoke about the only two recognised quality awards he has encountered in the world—the Malcolm Baldrige National Quality Award and The Deming Prize. These awards are not just about product quality but also about organisational quality.

Sekhar highlighted Deming’s theory of knowledge. He said that experience adds value when you’re able to predict the performance of your systems. This ability to predict means that you have the wisdom of experience; otherwise, it is the arrogance of experience that makes people use their time in the industry as a reason for credibility in terms of problem-solving.

In conclusion, Sekhar said, “If you analyse your company the way I have discussed using a systems thinking method, your company can be widely successful despite competition — provided the right questions are asked.”

“Packaging, samples or labels, cut it well” - The Noel D'Cunha Sunday Column

PrintWeek Team — Sun, 02 Apr 2023 01:00:00

PrintWeek (PW): Covid-19 has had a significant impact in the last three years. How has Valloy's performance been in these difficult times?
Juan Kim (JK): Valloy’s sales growth in 2020 was 140% and 190% in 2021. 2022 was a bit of a hard season because of the Russian war and currency rate crisis, but we showed 124% growth in 2022 too.

PW: What are the lessons learnt?
JK: 2019 was the hardest year for us but we survived. We have been preparing intelligent digital label cutters and it meets the market demand, because it is getting harder and harder to find experienced technical manpower in label converting companies.

PW: What does the concept of “customer development” mean to you?
JK: We run a start-to-end CRM system from lead finding to supporting and upselling to existing customers. To find the right potential target customers, it is the best to let them find us. We need to keep the industry leader’s position for this purpose by showing trust and intensive field knowledge by using reference sites.

PW:What is the coolest customer development case study you can share with us?
JK: Well, there’s a good example with Cricut, the makers of smart cutting machines that work with an easy-to-use app to help you design and personalise almost anything — custom cards, unique apparel, everyday items, and so much more. The company changed the manner of using a cutting plotter.

They designed the package and software looking fancy and user-friendly and bundling different tools and substrates, to give a variety of experience to users. By designing hardware and software to run the machines as IOT devices, we can develop some knowledge-based ideas to add more values, like supporting colour matching services online or providing a platform to share user designs over the user network.

About Valloy
Valloy is a Seoul-based South Korean venture company established in July 2004. The company specialises in development and marketing for digital software, imaging devices, printing and finishing devices, inks and substrates and next dimensional displays in signage printing, textile printing, interior decoration and label and packaging market. Industrial markets like printed electronics or bio-cell printing are another opportunity for digital production by inkjet technology.

PW: The K 2022 show in Dusseldorf and Labelexpo in India concluded on a high note. Three important exhibitions in Europe are lined up in 2023 and 2024, Labelexpo Europe in Brussels plus Interpack/Drupa in Dusseldorf. What should we expect from you at these shows?
JK: Valloy will participate in Labelexpo 2023 and Drupa 2024 to keep our brand power strong and empower our country distribution channels. We will show our new developments like Duoblade WS, which is a more affordable version of full automatic intelligent digital die cutter and Duoblade FX, which is man-less sheetfed digital craft machine supporting full cut, half cut and creasing together.

PW: Today, what are the industry standards for overall equipment efficiency (OEE)? What type of return on investment should we expect from an OEE program?
JK: We need to consider minimisation of quality loss, speed loss and time loss to have optimal OEE. We can improve quality and speed by upgrading hardware, because it is hardware performance.

But operation time is a different factor. We expect to run a machine at its 100% capacity but nowadays it is getting more difficult. Trend of shorter run orders makes us run the machine in batches and big investment on expensive machines will give you a pressure of regular bills for manpower, space rent, lease interest and so on. Instead of focusing on running big machines fully, we need to think about running multiple smaller but more flexible machines.

PW: India is a price-sensitive market, yet the trends are forever changing. As a mass producer of products, how does one stay relevant, and what innovations in products can one offer for consumers to create trends or disrupt the marketplace?
JK: Well, India is a huge market next to China. Trends are changing but people do not change easily. For example, label converters need to charge more for short run orders but customers do not accept it. We need to find and offer values of what digital machines can provide, like variable data or long length labels. It is also an idea to offer digital devices to end customers, not label converters. The key is how to make a total solution for ultimate simplicity and easiness with professional results.

Product spotlight: DuoBlade WX
At Valloy, we focus on digital label printing and finishing. While label converters may print quickly using a digital press, there is a bottleneck at finishing because you still need to order dies for cutting. Most converters have not moved to digital finishing because of speed. We solve this by offering a finishing machine with four cutting heads so you can cut four rows simultaneously. Moreover, our latest development in DuoBlade WX allows automatic job changeover using barcodes which are read by the CCD cameras. The selection of number of heads as well as distance between the heads is changed automatically depending on the job. We are thrilled to receive great market response for this all-in-one finisher WX which includes unwinding, laminating, cutting, matrix removal, and rewinding or sheeting.

PW: Do you see remanufacturing as a comparable option? One post-press equipment manufacturer has successfully repurposed binderies in the Indian market. What’s your view – advantages versus disadvantages?
JK: It is a good approach to provide higher added-value on existing devices. We also do remanufacturing of a simple Chinese digital die-cutter to convert it into an intelligent fully automatic digital craft machine, by changing boards and adding new tools, cameras, and sensors. This remanufacturing development can save cost and time but the new technology is dependent on old original technology, so a trustful relationship with old device manufacturers is important.

PW: The F&B packaging market in India is expected to grow from USD 33.2 billion in 2020 at a CAGR of 9.3% until 2026. We did a basic calculation that the consumption of packaged foods in India rose by 200% during the previous ten years, from 4.3 kg to 8.6 kg per person per year. Additionally, the beverage industry accounts for around 23% of all PET applications in packaging. The point is, consumption patterns are high in India. How does one manage a circular economy under such circumstances?
JK: It is a complicated issue. Basically printed PET cannot be recycled, mainly because chemicals can contaminate cleaning solutions. So we use sleeves for easy peeling and recycle unprinted PET bottles. Some beverage brands use embossed bottles to show their logo in an unprinted way. The latest research for artificial structured colour is quite interesting, because it makes colours without colourants. However we do not see 100% satisfactory answers so far.

Valloy is focusing on its new sustainable substrate – Limepaper, which is made of 30% plastic and 70% stone. We can find various applications like plant jars, cell phone cases, backlit film, name cards, books, catalogues, and labels.

PW: How do you address greenwashing as part of your sustainability / circular economy communications?
JK: Campaigning for brand power enhancement or investor attraction, many companies are bringing a concept of circular economics and sustainability. It is a good sign to educate the market first. The rest is a role of the government, to make the right regulations and conditions to get green marks or similar certificates, by analysing actual results of their activities.

PW: The structural design of packaging, which embraces a pack’s shape, texture, materials and product delivery capability, has mostly stayed the same. How should the industry approach structural packaging innovation? Through new product formats; new offerings like paneer and craft beer; eco-friendly, increased shelf life - MAP (modified atmospheric packaging)?
JK: We can find many innovative package structure designs by using less material while providing the same or better strength. Well-designed package structure can even provide fun to customers with positive impressions. These kinds of trials are attempted mostly in paper box design. But we also need to find a similar way of approach for packages which need perfect sealing like liquid or food.

About Juan Kim, CEO of Valloy
Kim majored in chemical engineering from Seoul National University (SNU) in South and got a master’s degree. His first job was as technical sales staff for artificial intelligent optimisation software in the petrochemical industry. His impression at this time to learn about soft power to get maximum efficiency in existing facilities is also helping to design and sell the current digital devices now. After establishing Valloy in 2004, Jim is developing digitally visualising technologies and solutions including inkjet printers, label printers, special inks, special substrates, and digital finishers, among others.

PW: The Government of India has set a vision of a USD five-trillion economy. In your view, what are the opportunities for the print and packaging industry - and your organisation - in India?
JK: Digital packaging is a trend. Even labour cost is relatively lower in India, but we cannot say experienced engineers for the traditional printing and finishing industry can be alive forever and young people would not learn about legacy technologies. So digital printers and finishers will be dominating the Indian market too. In the initial stage, high capacity expensive machines will be chosen by leading converting companies but people will find smaller and flexible solutions as time goes on.

PW: As and when the present USD 3.1 trillion economy grows to a USD 5-trillion economy, the Indian printing industry, particularly the packaging industry, will see substantial growth. One number says, the packaging consumption in India has increased 200% in the past decade, rising from 4.3 kg per person per annum (pppa) to 8.6 kg pppa as on FY20. How prepared are you to support the print and packaging factories in India?
JK: We aim to provide middle-level solutions to small and medium size factories with company, flexible and intelligent solutions including digital label printers and cutters. We’re putting the latest technologies into our devices to provide ease and fun for young engineers.

PW: In India, too many business owners talk about their machines and investments. Few focus on soft power. For example, culture, team-building, delegating, housekeeping, plus how to get optimum conversion costs and be much more efficient. Your view?
JK: We can help by providing compact size digital devices to improve the factory's working environment with less odour, less dust and less noise. When young people gather in the factory with new digital equipment, company culture will also change naturally.

At a glance: Juan Kim

Fav most app?
Kakao

Besides your phone and wallet, what are a couple of must-have items you always carry?
Ring and eCigarette

Window or aisle seat?
Aisle

Snack or meal?
Meal

Cocktail or diet drink?
Cocktail

SUV or luxury?
SUV

What’s the current author you are bingeing on?
Takehiko Inoue

One celeb who you met who has impressed you?
No one

First thing you notice in a biz meeting?
Voice

One question you always ask when you are hiring?
Sensitivity and communication.

What’s the one thing you wish you knew at age 21?
How to lose gracefully.

What’s the best piece of advice you’ve received?
You are doing well.

“After Japan and China, it is India which has the most Komori service staff” - The Noel D'Cunha Sunday Column

Noel D'Cunha — Fri, 24 Mar 2023 17:12:00

PrintWeek (PW): 2022 is behind us. What does your 2022 report card say?
Satoshi Mochida (SM): 2022 was the year of the new normal, and the recovery of international business confidence. However, the business struggled in the second half of the year due to the impact of the zero-Covid policy in China. As a manufacturer, in addition to the global semiconductor shortage, soaring steel and energy costs have had a major impact on manufacturing costs. The effect of the weaker yen (a tailwind for overseas exports for our company) worked in a favourable direction, but we should not count on this.

PW: The years 2020 to 2022 have been volatile. How has it been for you, expansion or status quo? Lessons learnt?
SM: The economic slowdown caused by Covid-19 affected us in the same way. Digitalisation made progress due to Covid-19, and what is and is not necessary became clear. I think the same thing is happening in the printing business. There are still a lot of necessary printed materials, and we believe that paper media has great potential.

PW: What does the concept of customer development mean to you? What is the coolest customer development case study you can share with us?
SM: Now is an age in which it is difficult to develop products that can dominate globally with just one product or specification. We believe that customer development is about creating products that meet customer needs in each market and creating new business models with customers. In these circumstances, we believe problem-solving, especially in Asia, is one of the strategies that Komori should pursue.

PW: The K in Dusseldorf and Labelexpo in India concluded on a high note. Three important exhibitions are lined up in 2023 and 2024, Labelexpo Europe in Brussels plus Interpack/Drupa in Dusseldorf. What should we expect from you at these shows?
SM: At this moment, we are planning to exhibit at Drupa. Other exhibitions are undecided, but Komori will promote automation that eliminates simple work from the manufacturing site and maximises labour productivity based on the concept of connected automation. At IGAS, held in Japan in November 2022, production visualisation and process linking using KP-Connect, Komori’s IoT cloud, autopilot for fully automated operation of printing presses, and logistics using a palletising robot and an AGV were demonstrated and well received.

In addition, I wish to strongly promote our efforts to address environmental issues. I would like to express specifically what Komori can do to address the issue of rising energy costs, which is a worldwide topic recently, and ultimately to achieve a carbon-neutral society.

PW: Are paper, paperboard, and label converters still managing business and manufacturing operations with industrial-age practices despite being a part of the knowledge age? Is there a knowledge gap in our industry? How do we bridge it? How do we convince Gen Z about the clout of ink on paper?
SM: As I mentioned, paper media is undergoing major changes since the outbreak of Covid-19. Currently, with the problem of eliminating plastic, paper containers are booming, and paper media is enduring by changing with the times. I think we are getting closer to products that directly appeal to consumers each time. I can’t imagine exactly what kind of paper media will emerge in the future, but I believe that printing technology and paper media will become even more closely related to the B2C business.

Komori Lithrone GX 40 press

PW: Today, what are the industry standards for overall equipment efficiency (OEE)? What type of return on investment should we expect from an OEE program?
SM: We can use KP-Connect to understand the operating rate of printing companies, but the OEE operating rate is generally low and varies greatly depending on the printed material (merchandise). I think OEE is effective if it is used as an index for a single company, but I think it is necessary to examine carefully to compare it with other companies and set general target values. We would like to visualise the production process more broadly, calculate the cost of each sheet, and enable judgments based on profit per hour.

PW: India is a price-sensitive market, yet the trends are forever changing. As a mass producer of products, how does one stay relevant, and what innovations in products can one offer for consumers to create trends or disrupt the marketplace?
SM: Looking at India’s demographic trends, I believe that India will become a centre of global consumption in the future. Markets with growing populations tend toward standardised trends, but in today’s digital society, information from throughout the world reaches individuals. It might be best to quickly incorporate worldwide trends and provide them in a form that matches the Indian people.

PW: Do you see remanufacturing as a comparable option? One post-press equipment manufacturer has successfully repurposed binderies in the Indian market. What’s your view – advantages versus disadvantages?
SM: Of course, the basic parts of printing presses are manufactured with durability that lasts for decades. We believe that remanufacturing is important in terms of acquisition costs and the environment. However, there is a large difference in productivity between modern machines and those from 10 years ago. Of course, the quality is improving dramatically.

Using remanufactured machines involves worrying about breakdowns and quality while using new machines changes the motivation of employees. We believe that the total cost of ownership (TCO) is higher for new presses. Also, when purchasing a remanufactured machine, we hope the user will purchase a product that has a manufacturer guarantee from Komori.

PW: The F&B packaging market in India is expected to grow from USD 33.2-billion in 2020 at a CAGR (compound annual growth rate) of 9.3% until 2026. We did a basic calculation that the consumption of packaged foods in India rose by 200% during the previous ten years, from 4.3-kg to 8.6-kg per person per year. Additionally, the beverage industry accounts for around 23% of all PET applications in packaging. The point is, consumption patterns are high in India. How does one manage a circular economy under such circumstances?
SM: For this, the only way is for all companies and individuals to raise their environmental awareness and deal with it under the initiative of the government. However, I believe that the printing industry is close to this activity. By changing from film to natural materials such as paper, and by making excessive packaging simpler and more functional, the printing industry can become a leader in creating a recycling society.

PW: How do you address greenwashing as part of your sustainability / circular economy communications?
SM: We are mainly a B2B business, and the environmental appeal of our products is rarely linked directly to the purchasing behaviour of consumers (purchasers). We plan to expand the supply of environmental information in the future, and we are trying to clearly put forward the facts based on actual data.

The Tsukuba plant consists of the factory, a research centre, KGC - a training centre, and facilities that benefit the employees

PW: The structural design of packaging, which embraces a pack’s shape, texture, materials, and product delivery capability, has mostly stayed the same. How should the industry approach structural packaging innovation? Through new product formats; new offerings like paneer and craft beer; eco-friendly, increased shelf life - MAP (modified atmospheric packaging?
SM: To take Japan as an example, despite a high cardboard recycling rate, many people still dispose of paper packaging as household waste. In terms of materials, we believe surface processes, such as PP film laminating, which is applied to improve the durability of, and waterproof paper containers and the use of plastic materials to show the contents will be reconsidered in the future.

One of these counter-measures is to create a design that encourages recycling while promoting the use of paper for packaging. In addition, the amount of paper made from waste materials (bagasse from sugarcane materials, apple tree branches cut down for growth, bananas, fallen leaves, etc) is expected to increase in the future. I hope that such a paper will be specified for packaging products from the planning stage.

Furthermore, paper container packaging in Japan is considered excessive in quality, such as a large number of individual packages, compared to other countries. In addition to being very strict about forming quality, a large quantity of inventory is often kept in anticipation of additional orders. As a result, a great deal of waste is due to defects and design changes.

We believe that digital printing systems will be a new solution for promoting on-demand printed products for packaging. By producing the necessary amount, we believe that we can handle smaller lots and convert to a system that does not carry inventory.

PW: The Government of India has set a vision of a USD 5-trillion economy. In your view, what are the opportunities for the print and packaging industry, and your organisation, in India?
SM: Of course, we also think that India will become a major market in the future. Our establishment of a local subsidiary in India in 2018 was in anticipation of this. However, the challenges faced by the Indian market are different from those of developed countries and areas. We believe that it is necessary to have a deep understanding of the printing industry and business in the Indian market, grasp the issues firmly, and introduce products suitable for India. One example is the Enthrone series of small sheetfed presses currently being shipped to India.

PW: As and when the present USD 3.1-trillion economy grows to a USD 5-trillion economy, the Indian printing industry, particularly the packaging industry, will see substantial growth. One number says, the packaging consumption in India has increased 200% in the past decade, rising from 4.3-kg per person per annum (pppa) to 8.6-kg pppa as in FY20. How prepared are you to support the print and packaging factories in India?
SM: As manufacturers introduce products for the Indian market, it will inconvenience our customers if we cannot provide after sales services suitable for the local market. The number of service staff in India is already next only to Japan and China, and the number is increasing every year. In the words of Komori’s chairman, “Komori’s basic idea is that the sales department sells the first machine, the factory sells the second machine, and its service sells the third machine.”

PW: In India, too many business owners talk about their machines and investments. Few focus on soft power. For example, culture, team-building, delegating, housekeeping, plus how to get optimum conversion costs and be much more efficient. Your view?
SM: I think it’s proof that consumption power is vigorous in the economy. If consumption power declines, the one-way power of firms is dispersed. In this case, soft power helps a lot. By defining the company’s mission and vision and clarifying the employee code of conduct, it becomes possible to direct the vector of these dispersed employees in one direction. I think it is important to make such efforts while consumption power is strong. It will lead to great assets for the future.

PW: One takeaway from your autobiography (if you write one) ...
SM: Persistence pays off.

Satoshi Mochida: at a Glance

Fav most app?
Teams.

Besides your phone and wallet, what are a couple of must-have items you always carry?
A handkerchief.

Window or aisle seat?
Window seat.

Snack or meal?
Meal.

Cocktail or diet drink?
Cocktail.

SUV or luxury?
SUV.

What’s the current author you are bingeing on?
DT Suzuki (An Introduction to Zen Buddhism).

One celeb who you met who has impressed you?
Chiune Sugihara (for his humanity and strong will).

First thing you notice in a biz meeting?
Mistaken views due to prejudice and superficial analysis.

One question you always ask when you are hiring?
Language ability.

What’s the one thing you wish you knew at age 21?
Problems can be discovered for the first time by describing an ideal.

What’s the best piece of advice you’ve received?
Hold firm to one’s principles.

Helmut Huber: The Indian film industry is striving for future developments - The Noel D'Cunha Sunday Column

Noel D'Cunha — Sun, 29 Jan 2023 08:00:00

PrintWeek (PW): 2022 is behind us. What does your 2022 report card say?
Helmut Huber (HH): With a special view to India, whereas the country traditionally has a high demand for oriented polyester (BOPET) packaging film and thus for appropriate stretching technology, last year showed a clear trend towards BOPP film applications (oriented polypropylene). And Bruckner’s hybrid plant concepts for the production of BOPP as well as BOPE films are a success. Several lines were sold in 2022.

We expect demand in this field to rise worldwide and steadily in the coming years. And recently, there has been a slow but sure demand in India for lines to manufacture specialty films, especially for the rapidly growing eMobility sector. Two examples: ultra-thin films for highperformance capacitors and battery separator films for lithium-ion batteries.

PW: The years 2020 to 2022 have been volatile. How has it been for you, expansion or status quo?
HH: In the years 2020, 2021, 2022, the market for packaging films has really exploded worldwide — and, as a result, the demand for film stretching lines from Bruckner Maschinenbau has increased significantly. One reason for the development is that topics such as hygiene and food safety have become much more important in the packaging sector worldwide. In addition, food retailing and mail order have recorded international growth.

In 2020, Bruckner Maschinenbau’s turnover in complete lines and equipment for the plastics and film industry was around Euros 400-million, in 2021 already around Euros 500-million. A record turnover of more than Euros 800 million is expected for 2022, due to the simultaneously high demand for packaging and technical films.

PW: The K in Dusseldorf and Labelexpo in India concluded on a high note. Three important exhibitions are lined up in 2023 and 2024, Labelexpo Europe in Brussels plus Interpack/Drupa in Dusseldorf. What should we expect from you at these shows?
HH: The K show has demonstrated how great the need for personal meetings and face-to-face communication is — on our side but also with the customers. Our stand was exceptionally well attended, and we were particularly pleased with the many Indian customers; it was overwhelming to welcome them again in person.

In 2023, our trade fair focus will be on our main markets, with Plastindia and Chinaplas within the first four months. There we will present technical innovations for the growing technical film markets but also for the continuous demand for highly efficient packaging film production lines. And we also expect discussions about the future of plastic films — a sustainable film production.

PW: The structural design of packaging, which embraces a pack’s shape, texture, materials and product delivery capability, has mostly stayed the same. How should the industry approach structural packaging innovation?
HH: The preservation of nature by using resources and products responsibly is one of the major trends within our industry and markets. For example, we are developing packaging films that are becoming thinner and thinner on the one hand, but retain their protective function on the other. In this way, raw materials can be saved and the valuable commodity food can still be protected as long and as well as possible.

Another focus is on mono-material films for a circular economy. Together with various partners, Bruckner has developed mono-material packaging solutions to close the life cycle of plastic packaging and for best recycling raw material quality in new products. And this research and development is ever ongoing. Besides the state-ofthe-art materials, BOPP and BOPET, a new opportunity is opening up with BOPE.

As the demand for innovative BOPE films is only now starting to develop, Bruckner’s unique hybrid lines allow to react swiftly and flexible to market trends by also producing BOPP specialties such as UHB films and coated films alongside conventional packaging film. The hybrid concept is very well received, especially by Asian film producers.

PW: The Government of India has set a vision of a USD 5-trillion economy. In your view, what are the opportunities for the print and packaging industry, and your organisation, in India?
HH: In the field of flexible packaging, India has always been on a high-quality level, with future-proof investments and equipment. Indian film producers traditionally have a good feel for technology trends and in recent years are also heavily investing in Europe, Africa, Southeast Asia and the Americas. In addition, India is one of the rare countries where the availability of skilled workforce will not become a problem.

With their large number of talented engineers, the Indian film industry is striving for future film developments. Clear sign for this: The R&D teams at the Bruckner headquarters are working closely with Indian packaging, film and resin producers on new film types.

PW: As and when the present USD 3.1-trillion economy grows to a USD 5-trillion economy, the Indian printing industry, particularly the packaging industry, will see substantial growth. One number says, the packaging consumption in India has increased 200% in the past decade, rising from 4.3-kg per person per annum (pppa) to 8.6-kg pppa as in FY20. How prepared are you to support the print and packaging factories in India?
HH: With booming economy, availability of talented engineers and potential for growth, India has always been one of the important markets for the Bruckner Group companies. The entire group has been serving its customers in Indian subcontinents for over five decades with fast service and absolute proximity to local markets.

Our Indian subsidiary Brueckner Group India is strategically located at Navi Mumbai and operational since 2001. This modern set-up has been constantly expanded. Today, it has a strength of over 100 employees and supports all the group companies. The team extends business development and customer services support for all the packaging solutions provided by the group. Especially for our customers in the biax film area, there is a full-fledged clip and chain refurbishment centre as well as a supply chain and quality assurance set-up for high precision components.

PW: One product in your company portfolio that was a star?
HH: In December, we succeeded in putting a very special film stretching line into production, together with a long-standing Indian customer. It is our first 10.4-m wide, 600-m/min fast BOPET production line with direct film casting and special multigap stretching technology in India and it is also the first one in this country with a brand-new and unique film transportation system.

At a glance

Fav most app? The app of the German Alpine Association.
Besides your phone and wallet, what are a couple of must-have items you always carry? A laptop or tablet and an SOS emergency card for worldwide travellers.
Window or aisle seat? Aisle (for long distance flights). Snack or meal? Meal.
Cocktail or diet drink? Cocktail.
SUV or luxury? SUV.
What’s the current author you are bingeing on? Simon Sinek.
One celeb who you met who has impressed you? Not celebs in the traditional sense, but some owners and managers of our customers really impress me.
First thing you notice in a biz meeting? Which charisma emanates from which participant.
One question you always ask when you are hiring? Why are you applying for a job in Bruckner and what do you imagine the Bruckner spirit to be?
What’s the one thing you wish you knew at age 21?How important family and friends really are! But principally my motto is: Think positive and take it as it comes.
What’s the best piece of advice you’ve received? Don’t make every problem your own and don’t try to please everyone all the time

Mapping the sustainability quotient: Are we doing enough?

Rahul Kumar — Thu, 03 Mar 2022 08:45:00

For UFlex, sustainability is an overarching theme that drives the company. For the company, sustainability includes elements such as recycling, biodegradation, source reduction and source substitution.

“In each of these domains, we carry out rigorous work to not just be perceived as a sustainable company but actually execute sustainably-led projects at ground level and create products that translate into minimum negative impact on our environment. We follow all certified processes under international standards,” says Jeevaraj Pillai, joint president, flexible packaging and new product development, UFlex.

The company has various certifications for different activities which fall under the umbrella of sustainability. For Example, the company develops PCR-grade film made from PET waste under the brand, Asclepius, which is FDA compliant. It also has Kingfisher certification from SCS Global Services that endorses that the company’s PCR-grade films contain minimum 100% post-consumer recycled PET content. This certification corroborates to its customers and to the flexible films’ market, the integrity of its supply chain and claims regarding PCR-based film technology.

The company recycles industrial as well as post-consumer MLP waste at its Noida plant and this process has attained CIPET certifications in compliance with IS14534:2016.

“Also, our enzyme-based biodegradable technology, Flexzyme, biologically degrades packaging waste into CO2, water, and biomass in a few months when exposed to natural soil conditions. This technology is compliant to ISO 17556,” Pillai adds.

Meanwhile, Chiripal Poly Films has product sustainability certificates for PCR-based BOPET film. For the system, the company has the environmental management system certification (ISO: 14001-2015) and it is going for energy management system certification (ISO:50001-2018) by February 2022 and for international sustainability and carbon certifications in July/August.

Pillai says these certifications endorse the company’s efforts to make its processes sustainable. “It also helps the brands we work with feel more confident about UFlex, as a partner, in their sustainability journey. However, they don’t provide any framework or pointers towards our sustainability approach. There is a charter we have arrived at based on the government policies, our own requirements and capacities, and we follow it to the tee,” he adds.

Bikash Debnath, senior general manager, QA & TS, NPD, Chiripal Poly Films, adds, “Our 14001-2015 compliance which covers GPCB guidelines. The further implementation of the two new systems of EnMS/ISCC will strengthen our commitment towards environment and sustainability.”

Staying informed
How do the companies stay informed about the government regulation and policies?

Pillai says, “In India, government policies that are relevant to plastic packaging companies are Plastic Waste Management (PWM) and Extended Producer Responsibility (EPR) guidelines, which are prescribed by the ministry based on India’s engagement in climate change pacts and further imposed by the state governments on manufacturing entities. We are notified by the government about these policies and rules that each plant/factory in that state has to comply mandatorily.”

UFlex also has a full-fledged sustainability department with required expertise to prepare actionable reports. The company has been drafting these reports every year. “Most of the global customers we work with need these reports, as per their country’s federal policy, to verify if their packaging partners are showing a declining carbon footprint trend and we do share it with them. To give you a quick reference of the UFlex carbon footprint study, in 2017 our average CO2 emission was 2.38 tonnes per tonne of laminate and in 2020, it came down to 1.99 tonnes,” Pillai says.

Debnath says Chiripal regularly liaisons with the MoEF, CPCB and other government departments and agencies for updates on government policies and programmes. “We are also members of various industry bodies and the Film Manufacturers Association through which we interact and voice our views to the policy-makers,” he said, adding, “I would also like to mention that we are working closely with government bodies to collect and recycle plastic wastage from the villages in Gujarat.”

Pankaj Poddar, Group CEO, Cosmo Films, adds, “Our legal department keeps a track on all the notifications which are released from the government bodies. Additionally, we take a step further and keep discussing new sustainability norms with our customers, suppliers and different industry associations.”

Pankaj Poddar of Cosmo Films

The sustainability journey
During an industry forum in 2016, Cosmo Films shared a paper on how sustainability will in due time become important, the myths around plastics and how it’s more sustainable than any of its counterparts. The paper was appreciated by the delegates.

Poddar says, “We believe sustainability as a concept should be calculated as a whole, not just by its visibility. Plastics have the least amount of carbon footprint during manufacturing and transportation when compared to its counterparts, such as glass and paper. If collected, segregated and recycled in an orderly fashion, it is truly a wonder material which has reduced all round food wastage due to its barrier properties.”

Chiripal’s journey into sustainability has various goals. According to Debnath, it includes minimal use of natural resources and more use of renewable energy, such as solar, wind, hydro; and zero discharges of water. It also includes using energy efficient motors wherever possible, reducing carbon footprint, following the 3R principle and spreading awareness about the sustainability journey within the company and outside.

For UFlex, as a growing flexible packaging company, when it set up its business, its chairman Ashok Chaturvedi had estimated a proportionate increase in plastic waste with the increase in urbanisation. With a vision to provide convenience of flexible packaging to brands and consumers, UFlex ascribed equal importance to tackle the problem of plastic waste way back in 1990s and developed a technology to recycle MLP mixed plastic waste generated from its production way ahead of other companies in developed economies. This even earned the company the ‘Best Paper Award’ from Davos Recycling Forum in 1995.

“However, we were practicing a linear economy then,” Pillai says, “Once we had the technology to recycle waste, including one that homogeneously recycles all layers of MLP without the challenge of separating them, our next step was to bring in the recycled product into usage to create a circular economy.”

The company achieved that by manufacturing injection moulding components with recycled granules as well as by upcycling recycled chips into its PCR PET and PCR PE range of films.

“Then came the next challenge of reducing plastic consumption at source and we established that via our packaging solutions like Kraftika and more such solutions that use less amount of virgin plastic. Once we were successfully able to carry out meaningful work in all these three areas — first recycle, then make use of recycled products and then reduce the use of plastic at source to achieve circularity — that really was a true point in UFlex’ sustainability journey,” he adds.

Jeevaraj Pillai of UFlex

Setting targets
Do the companies conduct wider footprint assessment to help identify parts of the supply chain that are responsible for a high amount of carbon?

Pillai says UFlex does it on a periodical basis. “With that, we have been able to transform all our packaging plants into zero emission plants. The by-products are recycled and reused. The water is recycled, treated and reused. We have maximised the use of clean energy. Also, most of our plants are built closer to the customer base thereby reducing CO2 generated from freight/shipment cost,” he said.

Debnath says Chiripal will start carbon footprint assessment during implementation of ISCC from April 2022 onwards.

Meanwhile, Cosmo Films has recently created an assessment, and identified 20 new projects. These are underway to improve the company sustainability standards. “We already have several sustainability practices in place, which are helping us to reduce our carbon footprint,” Poddar says.

These include optimising its truck load capacities to improve fuel efficiency and to reduce gas emissions. The company is also working towards rainwater harvesting, and reducing water consumption at the production level to become water positive.
It has also partially shifted to renewable power sources, such as wind and solar energy at all its plants, which has helped in reducing its production of carbon footprint by a large margin.
“We are constantly innovating to manufacture products which are mono material, are easily recyclable, and that the post-recyclate polymers garner better value in the system since they are close to virgin polymers,” Poddar explains.

Switching to green energy
Poddar says Cosmo Films is working on a hybrid energy model at its plants, where the company partially uses solar and wind energy to power its plants, along with some amount of coal-based energy. “We are making a Rs 100-crore investment to include several new practices and projects to improve our sustainability standards,” he adds.

Debnath says Chriripal has already established a 4MW solar plant and a 2MW wind energy plant on site. “We are also focusing on purchasing more renewable energy,” he says.

The company is also switching from conventional light to LED. It is also providing training to its employees on energy management.

UFlex has made 100% LED lighting across all its plants. All its energy production at plants is through clean gas like PNG. “Moreover, the energy usage in processes has been reduced by substituting it with efficient process aids like electron beam curing, LED curing, transitioning to water-based inks, etc,” Pillai says.

Bikash Debnath of Chiripal Poly Films

Sustainability champion
Pillai says UFlex has an active sustainability department that evaluates every project, every process, each initiative, and suggests actionable upgraded plans to achieve a greater sustainability footprint.

“We have a full-sized recycling plant in Noida that recycles close to 30,000 tonnes of plastic waste per year as part of our sustainability goals in India. Our target is to recycle 100,000 tonnes of plastic waste every year. This we will achieve as we commission our recycling projects in Mexico and Poland. We have committed an investment of over Euros 15-million in expanding the packaging infrastructure between 2021-23 with sustainability at the core,” he explains.

Poddar says the entire management team at Cosmo Films is responsible to identify and implement best practices, which are to be followed for an eco-friendly environment at its manufacturing facilities. “Having said that, we are in the process of appointing people who would dedicatedly work towards suggesting and implementing sustainability best practices,” he adds.

Procurement practises
Including environmental requirements in procurement practices is an easy way of driving the right behaviours internally. What are the steps these companies follow?

Poddar says, “During procurement, we have a thumb rule. The raw material we procure has to be energy-saving, one which uses less water during the production process. We are also wary of harmful chemicals which might affect the environment. In fact, in our subsidiary, Cosmo Speciality Chemicals, all the raw material we procure is eco-friendly, and all our products are either GOTS certified or in process of getting certified.”
Debnath says Chiripal considers the supplier registration and evaluation. It also communicates its OHS guidelines with its suppliers.

Meanwhile, Pillai adds, “We are quite conscious of the suppliers that we work with. Most of our supplies and material is procured from big MNCs like Exxon Mobil, Dow, etc, who have robust and comprehensive sustainability practices in place.”

A part of the company’s DNA
Pillai says sustainability is very much a part of the company’s DNA. “At UFlex, we have been worried about the planet and economy. We have had zero emission and zero waste discharge plants since 1995. In fact, all our factories are designed to be zero emission and zero discharge both in terms of waste by-product and effluents,” he says, adding, “Moreover, we have moved towards offering a product portfolio in every business that is largely backed by the double helix of best technology and sustainability.”

Debnath explains, “Conducting business in a sustainable manner is the responsibility of any organisation, and we are no different. We believe that sustainability is a business approach which creates long-term value for us, our stakeholders, including customers and most importantly, the society we live in. So, for us, sustainability and working towards a circular economy is a part of our DNA.”

Poddar concurs that it is an essential part of the company. He says the company has set goals for itself and are working towards achieving them year on year. “We have several sustainability practices already in place, and are working towards several more in the years to come. One major portion of our investment goes into sustainability,” he says.

Some of Cosmo Film’s sustainability efforts includes improving waste collection and re-granulation process to increase production of usable RPG; design products with better process ability and standard formulation; maximise the use of reprocessed granules to manufacture other alternate usage components; buying waste and converting them to usable RPG; reducing quality return from customers by 25% and minimising waste reduction in the process, among others.

Christian Burattini: Sustainability and hygiene will dovetail

PrintWeek Team — Tue, 08 Feb 2022 09:00:00

PrintWeek (PW): Tough 18 months. Your learnings from 2021...
Christian Burattini (CB): High demand for hygienic and sustainable unit dose packaging in general, but especially hand sanitisers. I know this is happening, because about 90% of the enquiries I am now receiving have a key sustainability component. We think this will continue to be a driver for brands in the coming years. While we have offered recyclable laminates to customers almost from the outset, we expect to ramp that up to the point that by mid-2022, we are convinced that 75% of our sold laminates will be the recyclable version.

PW: How has your company and factory sites responded to the challenges of the Covid-19 era?
CB: We have experienced broken supply chains as one example. Our R&D strategy has been effective in addressing this issue.

PW: Anything on the ideas front? Any new research or innovation?
CB: For the past 24 months, we have been developing innovative and digital inkjet print modules using Memjet Duraflex fully integrated with our six-lane high-speed Alpha packaging machine. This development has been greatly appreciated by customers because with this integrated solution, they do not need to use external printers, cutting transport time and cost for short to medium production batches. They are able to produce everything on-site in a single workflow with a relatively compact footprint, and with equipment that is easy for one operator to manage.

PW: The pandemic has impacted India’s prospects to become a USD 5-trillion economy by FY25. However, has the last quarter numbers reposed faith in the Indian market?
CB: V-Shapes has several projects in India, from food and beverage to the medical device and cosmetics market. We see an increased demand in the area with a growing number of projects. We see India as a very important market, for us and for the industry as a whole.

PW: Brands (FMCG and non-FMCG) are seeking more and more from print and packaging. As a global manufacturing brand, how can our industry cater to the new normal of - gaining speed; more flexibility; profit-centric approach; and lower carbon footprint?
CB: Fillers/converters and brands alike should be seeking vertically integrated solutions that are in line with the technologies available today. That includes using recyclable/compostable substrates, minimising the total amount of packaging required, using packaging that minimises product waste and/or deterioration due to oxidisation, enabling on-demand manufacturing to produce exactly what is needed, and in a small footprint that has optimum energy and labour requirements.

PW: What do you feel are the operational benefits of such an approach?
CB: This approach provides producers and brands alike with shorter cycle times, faster time to market, and an innovative approach that will attract loyalty from eco-sensitive consumers, less waste, and a much smaller carbon footprint in the overall life cycle. If printing, converting and packaging can take place at the same locale, there is no need to ship heavy substrates around, from the supplier to the converter to the printer and back to the converter. Plus, more efficient packaging takes up less space in shipping, further reducing the shipping carbon footprint as well as costs.

PW: How should print adopt marketing strategies that promote the print brand beyond the function of product or service?
CB: We believe the key is to meet consumers’ immediate and emerging needs – often needs they didn’t realise they had until they experience innovative packaging. As with any transformational technology, end users, and even brands, often do not know what is possible. Thus, converters/fillers need to educate their brand customers about the possibilities, many of which we have laid out in this conversation. And brands, in turn, have a responsibility for helping to educate consumers about the availability and benefit of more sustainable packaging.

PW: One school of thought is, the key is to do more than just meet consumers’ immediate needs. What is your view?
CB: Digital technologies enable a seamless, end-to-end production process, from order entry through production and shipping all under one roof, with a substantially smaller cost and environmental footprint. We believe eco-conscious consumers, of which there are a growing number around the world, are very open to accepting a different type of packaging that meets these immediate and emerging needs once they are made aware of the possibilities.

PW: 77% of Indian consumers are actively engaging with sustainability. These consumers will invest time and money in companies that try to do good. Three sustainable actions you have undertaken in the past year that you can share with us?
CB: We developed a new fully recyclable mono-polymer polypropylene laminate for our sachets. The recyclability of these sachets has been certified by Interseroh and verified by Tomra. Second, as described, with our digital inkjet solutions we can cut the amount of transport required across the product lifecycle and therefore, offer a reduced environmental footprint.

PW: And the third?
CB: Our machines are low energy consumers; our sachets are efficient in terms of transportation, with less air both in sachets and packaging boxes for transport. This not only delivers a reduced environmental footprint, but it also ensures that the packaged product lasts longer with no risk of oxygenation as can occur when air head space is required. Plus, because a single operator can easily manage the entire process – even an operator who is not highly skilled – labour costs are reduced and it is easier to find the necessary labour even in a tight labour market such as the one we see today.

PW: Is there a Green Gap between what our industry talks about; and the rest of society? For example, the industry uses terms such as “biodegradable” and “circular economy”…
CB: Educating consumers in a transformational environment can be a challenge. It takes efforts on the part of the entire supply chain, from sustainable material providers such as Sihl, technology partners such as Siemens, and equipment manufacturers such as Trojan Labels and Memjet to fillers/converters and the brands they support. These stakeholders should work together to ensure accurate, understandable messaging gets out to consumers in the places they frequent – online and in person.

PW: How can we bridge the knowledge gap?
CB: Too often, we are talking to ourselves, and that doesn’t help bridge the gap. But if done right, the rewards are there. The online economy and social media offer one avenue for this education, especially if the stakeholders can create viral promotions. At the same time, there is for sure plenty of green washing occurring in the market. And that is counter-productive. At V-Shapes, we follow directions from Ceflex, working with third-party certification bodies like Interseroh, TUV Austria, partners like Natureworks and Tomra, to mention a few. In this way, we make sure that we follow the best guidelines and get support from market leaders. We believe this is the best model and we wish more participants in the market would follow this lead.

PW: Any lessons you can share from a customer that have been resilient or innovative (and flourished) during the past 18 months?
CB: Health Supply US (HSUS) acquired two of V-Shapes Alpha single-dose packaging machines and a V-Shapes Dflex nearline digital printing solution. Managing partner of HSUS Cesar Garcia had this to say, “Our original plan was to contract out the manufacture of single-dose branded sachets of hand sanitiser we could hand out at events and for other uses. But it quickly became evident that it made more sense to actually install the equipment in our North Carolina plant. And once we installed our first Alpha and were on our way to our second, it also became clear that we could easily do on-site printing rather than outsourcing it with the VS Dflex printer.”

PW: Please explain the technology that is being referred to…
CB:AlphaFlex print-FFS machine from V-Shapes, developed in partnership with Memjet and ColorGate enabled an on-demand production of single-dose sachets for Air Canada’s use, with high-quality synchronised printing on both sides. The sachet structure also provides one-handed opening.

PW: One outrageous prediction for the year to come...
CB: Sustainability and hygiene will dovetail to create a new set of demands on packaging providers. These will become more important than fancy graphics and bright colours. That being said, high quality printing will still be required but may not be the driving force behind shelf appeal that they have been in the past.

QUICK FIRE QUESTIONS

How do you unwind?
I play the piano.
One piece of music you love?
Anything by Debussy.
Favourite film?
The movie I remember a little linked with printing / printing presses, is 7 Pounds with Will Smith, but, my favourite movie is Interstellar.
Three books by your bedside?
Le Comte de Monte-Cristo by Alexandre Dumas, The Ghost in the Atom: A Discussion of the Mysteries of Quantum Physics by Paul CW Davies and Julian Brown and The Biography of Mario Draghi.
One thing about print you always utter in a public forum?
That printing is the most problematic part of the flexible packaging.
Recent packaging innovation that you loved?
I have not physically seen new things around for some time. Maybe the Winpak flexible PET with a coating that automatically sterilises itself thanks to a micrometric texture that doesn’t let the virus stay on the surface.
One tech-guru (past or present) you want to meet - and why?
Thomas Kurian, the chief executive officer of Google Cloud. He is the epitome of innovative thinking, and he is from India.

Rick Michelman: Emotions, experiences make connections

PrintWeek Team — Tue, 08 Feb 2022 09:00:00

PrintWeek (PW): Tough 18 months. Your learnings from 2021...
Rick Michelman (RM): In the last 18 months, we were reminded that staying true to our core values is the key to success. For Michelman, our value of respect was paramount. It was critical to respect our Michelman associates and keep them safe from Covid-19. We were proud that our leadership in India secured vaccines for all associates and their families. It was also critical to respect the needs of our customers and overcome raw material and transport challenges. We worked with customers and partners to overcome supply chain issues and to determine what our products needed to do and how they measured success.

PW: How has your company and factory sites responded to the challenges of the Covid-19 era?
RM: The pandemic continues to bring significant supply chain disruptions and raw material availability challenges. Because of this, Michelman has used our deep formulation and application expertise to innovate products to counter these challenges. Our solutions for compostable packaging for the food industry were well received and won many awards throughout Asia. The Indian Flexible Packaging and Folding Carton Association (IFCA) recently awarded Michelman India an IFCA Star award for our work in this area.

PW: Anything on the ideas front? Any new research or innovation?
RM: The eCommerce companies are subjected to various global and local regulations, so they have been forced to develop and utilise recyclable packaging for deliveries. Additional regulations are also forcing secondary packaging made of plastic to become recyclable, so not to generate more landfill waste.

Our team in India worked with several eCommerce companies to develop paper bags and help them make the jump from plastic to paper packaging – a significant step forward for India. We innovated both external water resistance and an effective inside heat seal to form the paper bags, ensuring the ability to send all paper bags into the paper recycling stream. Our solutions were developed specifically for both performance and sustainability needs. We see this segment growing significantly in the year ahead.

PW: The pandemic has impacted India’s prospects to become a USD5 trillion economy by FY25. However, has the last quarter numbers reposed faith in the Indian market?
RM: We never wavered in our belief in India. We are committed to our triple bottom line of people, planet, and profit. We did not alter our staffing plans or decrease investment in innovation or our associates. We remain highly optimistic about India’s printing and packaging markets, including flexible packaging with mono-material and mono-web structures for more efficient recycling, plastic to paper conversions, specialty printing, and digital printing. Our advanced materials also offer solutions for the fibres and composites and industrial coatings industries.

PW: Brands (FMCG and non-FMCG) are seeking more and more from print and packaging. As a global manufacturing brand, how can our industry cater to the new normal of - gaining speed; more flexibility; profit-centric approach; and a lower carbon footprint?
RM: Besides government paperwork, Michelman has always viewed India as a fast-moving and genuine creative space. We often start new technologies in India, thanks to our high-quality team’s ingenuity and their great collaboration with our Indian customers, partners, and brand owners. Organisation-wide we focus on creating a planet-positive footprint by reducing our water usage, energy use from non-renewable sources, and solid waste.

In addition, we focus on developing planet-positive products and solutions by zeroing out certain chemistries and eliminating volatile organic compounds, light-weighting, and the circular economy.

PW: How should print adopt marketing strategies that promote the print brand beyond the function of product or service. One school of thought is, the key is to do more than just meet consumers’ immediate needs. What is your view?
RM: At Michelman, we think about the customer experience. We want to keep the food fresh and make an easy-to-open pouch. We help companies create great graphics on any substrate through different print techniques. We help enhance the customer experience with technology, enabling customised print, highlighting a local connection or functionality that gets consumer attention. Emotion and experiences make connections for brands, and at some level, that makes it fun to be a part of this industry.

PW: 77% of Indian consumers are actively engaging with sustainability. These consumers will invest time and money in companies that try to do good. Three sustainable actions you have undertaken in the past year that you can share with us?
RM: We are deeply committed to sustainability and delineate our behaviour into a few different categories. We believe in helping the communities in which we work and live - thrive. We facilitate a “global day of service” every September where our associates leave their cell phones and computers behind and volunteer together in their local communities.

While those we assist appreciate it, our associates genuinely benefit from the experience. In 2021, our India team drove to a facility for girls a few hours outside of Mumbai to assist them with building repair and grounds maintenance. Our team also interacted with them to motivate them to pursue their dreams. This was an incredibly rewarding day for all involved.

PW: Is there a Green Gap between what our industry talks about; and the rest of society? For example, the industry uses terms like “biodegradable” and “circular economy”. How can we bridge the knowledge gap?
RM: Michelman is full of well-positioned leaders that can teach the importance of sustainability throughout the industry and to consumers. We can demonstrate how everyone in the value chain can participate in the circular economy and share a roadmap of the steps along the way.

Eventually, packages will denote how the user can dispose of the item responsibly and conveniently. We’ll have to be active, as the average consumer will not be able to connect the dots without our industry’s support and coaching. They likely want to support the vision, but they might not yet know how to or understand the terms. We can get them there!

PW: Any lessons you can share from a customer that have been resilient or innovative (and flourished) during the past 18 months?
RM: As discussed previously, we learned a lot from our work with eCommerce companies. We’ve also learned from developing more sustainable paper cups and edible oil pouches.

PW: Disposable paper cups are a significant sustainability issue…
RM: Yes, because they are not recyclable, contrary to common belief. Their plastic lining ensures that they rarely make it to a recycling plant (regardless of what bin you put them in), and they are not biodegradable. As a result, they are currently the second-largest litter waste product, second only to plastic bottles.Current paper cups are made out of paper and are coated with low-density polyethylene (LDPE) or wax to prevent liquid from leaking out or soaking through the paper.

Our team of experts in China has successfully developed and tested a new coating solution, which eliminates the plastic lining used in conventional paper cups and eases the recycling and re-pulping process. Along with recyclable and re-pulp-able properties, it also provides excellent water, oil and grease resistance and very high seal strength. It has been tested successfully for hot and cold applications.

PW: What about edible oil pouches?
RM: Indian consumers for the edible oil industry used pouches with a 5-7-layer coextruded film that combines PE, tie-layer, nylon, or ethylene vinyl alcohol (EVOH). Nylon’s incorporation in the structure provides puncture resistance & a moderate oxygen barrier. However, the presence of nylon or EVOH prevents this structure from easily being recycled.

Michelman has successfully developed a water-based coating solution that eliminates the need for nylon or EVOH but still provides freshness. In addition, oxygen barrier plays a vital role in preventing the oil from going rancid and extending its shelf life. Our objective is to optimise the coating to match or exceed existing oxygen barrier values to improve product shelf life and reduce the chances of rancidity. In addition, the elimination of nylon / EVOH makes this mono-material structure easily recyclable and compliant with the impending plastic waste management rules.

PW: Your plans for 2022?
RM: If I had my way in 2022, the world would safely return to international travel. And, of course, I would get back to India. Part of the beauty of the printing and packaging industries is the deep relationships we form, be that press side working through issues or having a meal discussing culture and family. Like many companies, we have deep respect for our customers, suppliers, and partners. That takes some effort, and it is always most rewarding in person, which makes travel necessary. And, as a company, we will continue to measure our success via our triple bottom line and work towards our goals of people and planet, not just profit.

PW: One outrageous prediction for the year to come ...
RM: 2022 will be slightly less absurd than 2020 or 2021. But maybe I shouldn’t jinx it, as we have all learned over the past few years that things can always get worse. That being said, we all will be well prepared to use that acquired knowledge and experience for good.

QUICK FIRE QUESTIONS

How do you unwind?
I like to be outdoors – walking with my dog, riding a bicycle, or running (while my knees hold up), and I love snow skiing in the mountains in winter.
One piece of music you love?
Because I have unusual tastes in music, I listen to smaller, more independent bands. Past favorite musicians have been REM, Red Hot Chili Peppers, and Foo Fighters. If any readers know these, enjoy.
Favourite film?
I cannot say it is a favourite, but I did enjoy the new Dune movie. Not much print there, but a nicely-created world with great visuals.
Three books by your bedside?
I mostly spend time reading about today’s world. It’s fascinating, scary, and exciting.
One thing about the print you love to utter in a public forum?
Innovation lives here because industry players push each other toward excellence. The industry changes all the time, and it is fun to be part of it.
Recent packaging innovation that impressed you?
It is no surprise that the innovation in our industry is accelerating. We are all redesigning items for sustainability, ease of use, and enhanced customer experience. However, I get particularly excited by any innovation that engages mono-material solutions or plastic to paper conversions without losing needed performance.
One tech-guru (past or present) you want to meet - and why?
Throughout the pandemic, I have taken up astronomy and astrophotography. I would love to meet the early telescope creators, as they see objects never before observed.

Click here to read more about Michelman.

Eli Grinberg: Digital press process is less wasteful, cleaner, and faster

PrintWeek Team — Tue, 08 Feb 2022 08:00:00

PrintWeek (PW): Tough 18 months. Your learnings from 2021...
Eli Grinberg (EG): The pandemic is a historic period in our lifetime. My learnings so far are what I already believed – a business can continue even with an interruption such as Covid-19. The company’s flexibility to adapt, a good product, and having dedicated people to step up to a new challenge are vital. Luckily for Scodix, we possess these things.

PW: How have your company and factory sites responded to the challenges of the Covid era? Anything on the ideas front? Any new research or innovation?
EG: We launched the new Scodix Ultra 1000’s series of presses during the pandemic in September 2020, which further assisted with our vision of penetrating more into the packaging industry, especially with the B1 format. Our inventory was well stocked, so we did not have to interrupt deliveries with the onset of the supply shortages.

In addition, the Scodix Studio W2P and W2Pack automation platforms have also been launched in the past two years. They further helped our customers increase productivity as the world moved online so quickly since March 2020.

PW: The pandemic has impacted India’s prospects to become a USD 5-trillion economy by FY25. However, has the last quarter’s numbers reposed faith in the Indian market?
EG: Scodix has always had a belief in the strength of the Indian market. The printers were early adopters of Scodix digital enhancements, and the work is stunning and innovative. I look forward to the continued partnership between Scodix and the Indian print market.

PW: Brands (FMCG and non-FMCG) are seeking more and more from print and packaging. As a global manufacturing brand, how can our industry cater to the new normal of - gaining speed; more flexibility; profit-centric approach; and lower carbon footprint?
EG: Digital presses are the way forward, especially with embellishments, simply because the process is less wasteful, cleaner, and faster. These three components alone add value for any print service provider and brand. Brands are a significant driving force in our industry, and we see ourselves as their business innovator drivers. Digital industrial presses, such as ours, are continually pushing the limits to increase speed, add flexibility and provide better environmental solutions.

PW: How should print adopt marketing strategies that promote the print brand beyond the function of product or service? One school of thought is, the key is to do more than meet consumers’ immediate needs. What is your view?
EG: We have many customers that are marketing specialty print providers. They work with brands to produce a print with enhancement and a concept and value analysis. The concepts included are based on consumer research that the brand and printer use to develop a product that increases sales.

PW: 77% of Indian consumers are actively engaging with sustainability. These consumers will invest time and money in companies that try to do good. Three sustainable actions you have undertaken in the past year that you can share with us?
EG: Scodix solutions are approved for recycling. We still support the environment by eliminating plates, dies, moulds, solvents or chemicals. The Scodix polymers are certified as having no VOC emissions. Plus, Scodix has created an exclusive sustainability department within its structure. We print on CYMK prints that our customers and suppliers supply. Our customers and suppliers mostly are forest sustainability certified.

PW: Is there a Green Gap between what our industry talks about; and the rest of society? For example, the industry uses terms such as “biodegradable” and “circular economy”. How can we bridge the knowledge gap?
EG: Through education. Scodix does it through easy access and explanations of the sustainability story of our company (brochures, presentations, and videos) on the web, social media and other public platforms.

PW: Any lessons you can share from a customer that have been resilient or innovative (and flourished) during the past 18 months?
EG: Three areas come to mind on how our customers prevailed during the pandemic. The Anstadt Company – Matt Doran, CEO, stated that Scodixwas the most powerful brand equity building tool in its arsenal. The pandemic showed the power of digital with quick turnaround and easier processes for brands. CZK – Piotr Kulikowski, digital print director had commented that during the pandemic new leads had come from the combo of HP and Scodix. Supply and demand are key. LPI Letterhead produced Halloween boxes on the fly for Kate Weiser Chocolate and delivered the results.

PW: Your plans for 2022?
EG: To become the world’s largest digital provider of industrial product enhancement and decoration solutions.

PW: One outrageous prediction for the year to come ...
EG: As Scodix is a publicly traded company, I cannot provide an outrageous prediction, but I do hope that the world will open and tradeshows will come back.

QUICK FIRE QUESTIONS

How do you unwind?
Cycling and spending time with family.
One piece of music you love?
Daft Punk’s R.A.M.
Favourite film?
Pulp Fiction.
Three books by your bedside?
Sapiens:Start-up Nation by Dan Senor and Saul Singer; Principles by Ray Dalio; and A Brief History of Humankind by Yuval Noah Harari.
One thing about print you always utter in a public forum?
The enhancement is the last part in the printing process that will become digital, and Scodix is leading this revolution.
Recent packaging innovation that you loved?
Xiaomi smartphone packaging with Scodix.
One tech-guru (past or present) you want to meet - and why?
Johannes Gutenberg, his innovation started a huge revolution that is still rolling.

Peter Steinbeck: Hoping for a return to life of trade fairs and personal meetings

PrintWeek Team — Tue, 08 Feb 2022 08:00:00

PrintWeek (PW): Tough 18 months. Your learnings from 2021...
Peter Steinbeck (PS): There were no standard solutions for the challenges of the last 18 months. Trustful personal relationships, a lot of communication and tailor-made solutions were the things that were needed the most. During the crisis, we continued to find solutions together with our customers.

PW: How has your company and factory sites responded to the challenges of the Covid-19 era?
PS: We have implemented strict on-site security measures for our production plants and used home office, wherever possible. This way, we were able to minimise effects and stayed fully operational the whole time.

PW: Anything on the ideas front? Any new research or innovation?
PS: During the pandemic, our smart devices network that was in place had proven especially useful. When traveling was restricted, these well-established services helped us to support our customers. New methods such as visual assistance were used more extensively and gained market-share. Our local presence worldwide was also a major benefit during the times of travel restrictions. We could install and commission all the machines delivered to India even during the time of travel restrictions.

PW: The pandemic has impacted India’s prospects to become a USD5 trillion economy by FY25. However, has the last quarter numbers reposed faith in the Indian market?
PS: We see a lot of focus in the Indian market towards more sustainable flexible packaging solutions. We have always had a long-term approach in the Indian market and can mention that our approach is working very well with the recent results. The demand for sustainable solutions is opening new opportunities for growth.

PW: Brands (FMCG and non-FMCG) are seeking more and more from print and packaging. As a global manufacturing brand, how can our industry cater to the new normal of - gaining speed; more flexibility; profit-centric approach; and lower carbon footprint?
PS: Each year we invest around 8% of sales in research and development (R&D). We have a 10,000 sqm technology centre for customer tests as well as our own R&D. With these investments we constantly improve our machines to cater to needs for increased efficiency. One of the biggest levers is digitisation. Automation and assistance systems support operators to make the most of the machine. internet of things (IoT) systems give the transparency needed to improve processes. They are also the basis for transparency needed for sustainability.

PW: How should print adopt marketing strategies that promote the print brand beyond the function of product or service. One school of thought is: the key is to do more than just meet consumers’ immediate needs. What is your view?
PS: We have presented solutions to widen the function of print for the past years already. These included functional printing, for example to show shelf-life or an uninterrupted cold chain. Another example is the implementation of QR codes into the print motif. Until now, none of these solutions have gained a significant market share – mostly because packaging remains a very price sensitive market. Nonetheless, our machines are ready to support these novel approaches to make packaging more useful.

PW: 77% of Indian consumers are actively engaging with sustainability. These consumers will invest time and money in companies that try to do good. Three sustainable actions you have undertaken in the past year that you can share with us.
PS: As a machine builder our biggest impact is technology. These are our three most important developments: 100% recyclable all-PE pouches produced with Varex II and Machine-Direction-Orientation. The second was heavy duty sacks with a high content of recycled materials and lastly, an innovative solution for recyclable high barrier film: high barrier properties and recyclability by EVOH replacement with G-polymer.

PW: Is there a Green Gap between what our industry talks about; and the rest of society? For example, the industry uses terms like “biodegradable” and “circular economy”.
PS: As experts it is natural that we in our industry have more knowledge than the rest of the society. Even within our expert circles there are different levels of knowledge, when talking about sustainable solutions – for example in different markets. We see ourselves as ambassadors sharing the global best-practices with our customers. As for educating the public we believe we can only tackle this challenge together and actively support the activities of associations regionally.

PW: How can we bridge the knowledge gap?
PS: In India specifically we are working with multiple industry organisations to help spread the word and educate the society. We recently did an open to all webinar with VDMA and Indian Plastic Institute (IPI) on advancements in bulk material packaging in woven sacks where sustainability in bulk material packaging was discussed extensively.

PW: Any lessons you can share from customers that have been resilient or innovative (and flourished) during the past 18 months?
PS: Soparkar & Kothari Technologies (S&K) installed their first project for the hygiene film market realising the global trend toward multilayered blown film line. The company chose the best-in-class technology, Varex II with MDO line for manufacturing breathable and non-breathable back sheet films.

PW: And?
PS: Ultimate Flexipack has recently commissioned a set-up with a W&H blown film line with an inline MDO unit for developing single material laminates. This should be a landmark project for Indian flexible packaging industry opening new avenues in the direction of sustainability. We are very thankful to Ultimate Flexipack for extending their long-term partnership with us with this very important project

PW: Your plans for 2022?
PS: We will continue our chosen strategy in 2022. Efficient production, sustainability and digitisation will continue to be the core of our R&D activities. We are looking forward to K22 in October this year where we will launch marvelous innovations. To get even closer to our customers, we are actively increasing our team in global locations worldwide. We are close to having 100 people at our office in New Delhi and hope to add more in the coming months.

PW: One outrageous prediction for the year to come …
PS: Not outrageousness, but careful optimism will continue to be our approach. 2022 will be a transitional year in terms of Covid-19 with hick-ups in the global supply chains. We will all have to live with the side effects from these two severe hurdles while hoping for a return to life of trade fairs and personal meetings. We cannot wait to welcome more international customers in person again – on local trade fairs, at our headquarters in Germany and at the K22.

QUICK FIRE QUESTIONS

How do you unwind?
Family, travel, golf, reading and cooking.
Three books by your bedside?
Never by Ken Follet, Biography of Louis Armstrong and Principles by Ray Dalio.
Recent packaging innovation that you loved?
PET replacement in stand-up pouches.
One tech-guru (past or present) you want to meet - and why?
Steve Jobs – my user experience (UX) hero.