PrintWeekIndia - Latest Articles

Made in India: Rollers from Katsura India

Rahul Kumar — Tue, 22 Apr 2025 11:22:09

Established in 1899, Katsura Roller brings more than 125 years of expertise in roller manufacturing. As the pioneers of Japan’s printing rubber rollers, Katsura has established itself as a producer of rubber rollers.

With the vision to bridge the gap in the printing industry by providing rubber rollers to the Indian market at pocket-friendly prices, Katsura Roller India was formed as a joint venture company between Katsura Rollers Japan and Provin Technos. Katsura’s roller manufacturing expertise and Provin Techno’s sales and service expertise are at the company's core.

Katsura India is currently focusing on catering to the offset printing rollers market for oil-based, UV and combi-type rollers.

The technology
According to Akshay Kaushal, CEO of Katsura India, the technology has to do with the compound formulations that are carefully designed and developed to get the best printing results and life.

“We offer nitrile butadiene rubber (NBR) and ethylene propylene diene monomer (EPDM) printing rollers, which are suitable for oil-based, UV and combi applications. Our compounds offer excellent dimensional and hardness stability, excellent ink transferability, minimal heat build-up in high-speed runs and minimal changes in the nip width throughout the life of the rollers,” Kaushal says.

Katsura India began operations on 1 February 2025 and started deploying rollers. According to Kaushal, the company is currently producing rollers for offset printing machines of all makes.

Akshay Kaushal: Our goal was to offer high-quality rubber rollers at an affordable price

The market
Kaushal acknowledges that India is a price-sensitive market and asserts that Katsura’s products are competitively priced. "Our goal was to offer high-quality rubber rollers at an affordable price, and we've successfully achieved that. There are two perspectives: you can either pay less for lower-quality rollers and replace them twice a year, or invest a bit more in higher-quality rollers that offer better durability and consistent performance. High-quality rollers ultimately save time through easy maintenance, longer lifespan, fewer machine breakdowns caused by roller issues, and fewer printing problems. In the long run, this results in nearly half the cost for the printer."

He adds that customers consistently seek high-quality, precision rollers to ensure quality and uninterrupted output.

The Katsura Rollers USP
Kaushal states, “Currently, there is no standard quality being provided to printers in India. Printers experience significant variations in the rollers supplied with each batch. We’ve established a system that ensures all parameters are followed during production, and every roller leaving our factory is thoroughly inspected before delivery to customers.”

He adds that the company's compound quality is top-tier, with strong positive feedback from customers. “For example, our rollers offer excellent dimensional stability, outstanding glaze resistance, and minimal heat buildup at high speeds, which improves ink transfer and maintains a consistent nip width, resulting in longer product life,” he says.

Kaushal emphasises that the company’s compound is eco-friendly and phthalate-free, providing customers with an added benefit in meeting sustainability standards. "Many packaging companies are transitioning to sustainable packaging, and having an eco-friendly product in their press is a significant advantage."

He continues, “Given the quality we offer, we don’t see any alternatives that match up to our products. The closest alternatives on the market are at least 50% more expensive than ours.”

According to Kaushal, productivity is directly linked to the quality of the product supplied. “With our rollers, customers experience fewer machine stoppages due to roller issues and a longer product lifespan, which ultimately increases productivity,” he says.

He adds, “After switching to Katsura India rollers, our customers are using 80% less water with our dampening rollers and enjoying excellent ink transfer with consistently superb print results, which were previously inconsistent.”

Katsura India has also established an after-sales support team, backed by expert assistance from Katsura Japan.
Since the company is still in its early stages, Kaushal notes that its goal for the first year is for printers to experience the product's superiority and the improved results. “We are on track with this goal and are already receiving positive responses from customers,” he concludes.

Made In India: Super Bond Adhesives

Rahul Kumar — Tue, 25 Mar 2025 19:15:00

First things first. Priyank Agarwal, director, Super Bond Adhesives, says, Super Bond is expanding its manufacturing capacity of hotmelt adhesives from 11,000 tonnes to 36,000 tonnes to meet the increasing demand for adhesives across industries. This translates into a combined capacity of production to 70,000-mt per annum. This expansion will help the company enhance its production efficiency and cater to a larger customer base globally.

According to Agarwal, Super Bond’s new products, including Galaxy 12, offer improvements in curing time, bond strength, and environmental sustainability compared to older versions. These upgrades result in a boost in overall performance, reduced operational costs, and faster production cycles.

“Galaxy 12 was introduced at the PrintPack show as an innovative solution for customers who were using PUR adhesives. After testing, many customers switched to Galaxy 12 due to its superior bonding strength, faster curing time, and environmentally friendly formulation. It has become a preferred choice for firms looking for an efficient and sustainable adhesive solution,” he explains.

The group manufactures adhesives in three major chemistry formulations — hotmelt, water-based, and rubber-based. Each formulation uses cutting-edge technology to provide optimal bonding solutions for different industries.
Hotmelt adhesives bond instantly upon cooling, provides a quick and reliable solution for packaging, automotive, graphic arts, wood-working applications.

Water-based adhesives offer an eco-friendly bonding solution with strong adhesion and are mainly used in industries like packaging, graphic arts, wood-working, and others.

Rubber-based adhesives are known for their flexibility and durability, these adhesives are suitable for applications like footwear, foam furnishing, automotive, and heating, ventilation, and air conditioning (HVAC) systems.

Each adhesive formulation uses a unique combination of resins, polymers, and other chemical components to ensure strong adhesion, durability, and performance.

Brief history of Super Bond
Super Bond Adhesives was founded in 1974 and has established itself as a leading manufacturer of high-quality adhesives. Over the last 50 years, the company has continually evolved to meet the needs of various industries. It manufactures a wide range of adhesives, including hotmelt adhesives, water-based adhesives, and rubber-based adhesives.

With three production plants, Super Bond caters to multiple sectors such as packaging, graphic arts, automotive, woodworking, footwear, HVAC, foam furnishing, and mattresses. These plants are equipped with the latest technologies, ensuring superior product quality and scalability to meet diverse customer demands.

Super Bond's adhesives
Priyank Agarwal says, “Super Bond adhesives create strong bonds by leveraging a combination of polymeric resins, synthetic rubbers, and polyolefins. These adhesives bond materials such as paper, plastics, metal, rubber, wood, and foam. They work by forming a chemical or physical bond with the substrate, ensuring a reliable, long-lasting adhesion. The adhesives offer rapid setting times, excellent heat resistance, and high strength, making them suitable for both high-volume production lines and bonding applications.”

Super Bond caters to both B2B and B2C markets. Its products serve a range of industries, including packaging; graphic arts; automotive; woodworking; footwear; HVAC; foam furnishing and mattress manufacturing.

“These products are tailored to meet the needs of large industrial manufacturers as well as smaller enterprises requiring efficient, cost-effective adhesive solutions,” Agarwal says.

According to Agarwal, Super Bond provides cost-effective solutions while maintaining a high standard of quality. By manufacturing adhesives in three specialised plants and being located close to major ports, Super Bond ensures delivery to its customers.
“The company’s products are designed to offer quick setting times and high durability, which leads to better productivity and fewer rework costs. Additionally, the competitive pricing helps businesses in India remain efficient while maintaining quality in their operations,” he explains.

The customers
Super Bond has a global customer base that spans over 40+ countries. In India, Super Bond’s products are used across multiple sectors, including the automotive, packaging, and furniture industries. With a pan-India distribution network, Super Bond is able to cater to both large enterprises and smaller businesses across the country.

Super Bond's applications
The adhesives are used in a variety of industries, including packaging (carton-sealing and labelling); Graphic arts (wet and dry lamination, folder-gluing, book binding hotmelt); automotive (interior trim bonding); woodworking (veneering and furniture assembly); footwear (shoe assembly); HVAC and foam furnishing and mattress (foam lamination).

The technology
Super Bond focuses on innovation and sustainability by offering products that not only provide exceptional performance but also adhere to eco-friendly standards. The company regularly updates its formulations to meet the latest environmental regulations, ensuring its adhesives are safe for the environment and end-users. For example, the company’s water-based adhesives are designed to minimise the environmental impact compared to traditional solvent-based alternatives.

Super Bond adhesives are primarily composed of polyolefins (for strength and flexibility); EVA (ethylene vinyl acetate for heat resistance and bonding strength); rubber-based polymers (for flexibility and durability); and PVA (polyvinyl acetate for superior adhesion to various surfaces).

Agarwal says the company’s new Galaxy 12 is an adhesive introduced as a replacement for PUR (polyurethane reactive) adhesives. Galaxy 12 offers faster curing times, stronger bonds, and increased flexibility, all while being more environmentally friendly and cost-effective.

“It was introduced to replace PUR in applications like graphic arts and packaging. Customers have found Galaxy 12 easier to use and more reliable in high-demand environments, resulting in improved productivity and lower operational costs,” he says.

He adds, “Super Bond adhesives are designed to be user-friendly, with fast curing times, high bond strength, and versatility in application. Whether used in automated production lines or manual assembly, the adhesives are easy to apply, reducing the risk of error and ensuring high-quality results.”

Looking ahead
Super Bond is actively expanding its manufacturing capacity to cater to the increasing demand across various industries. The company is increasing its production capacity of hotmelt from 11,000 tonnes to 36,000 tonnes, significantly enhancing its ability to meet the needs of both domestic and international markets. This expansion allows Super Bond to better serve its growing customer base, improve production efficiency, and maintain its commitment to delivering high-quality products in a timely manner.

For 2025-26, Super Bond is focused on continuing its growth trajectory and strengthening its position as a global leader in adhesive solutions. The company aims to expand its market share in sectors such as automotive, packaging, graphic arts, and footwear. Additionally, Super Bond plans to introduce innovative and sustainable adhesive formulations to meet the needs of the customers.

While choosing an adhesive, customers seek:

Technological upgrades: Advanced formulations that deliver superior bonding.
Reliable after-sales service: Ongoing technical support and problem-solving services.
Material availability: Consistent and timely supply of adhesives to prevent production delays.
Sustainability: Eco-friendly adhesives that reduce environmental impact and comply with regulations.

Super Bond offers training programs for end customers, including line audits of original equipment manufacturers (OEMs) to ensure optimal adhesive usage; occupational hazard training to ensure safe handling and application of adhesives, and technical support to assist with the correct application methods, troubleshooting, and optimising adhesive performance.

Make in India: Premium News Fountain Solution from Orient NexGen Consumables

Rahul Kumar — Fri, 28 Feb 2025 10:37:00

The Premium News Fountain Solution is designed to optimise newspaper printing by addressing challenges and minimising costs, Rakesh Chauhan of Orient Nexgen Consumables, tells Rahul Kumar

Orient NexGen Printing Chemicals offers products that blend Western technology with Indian innovation. Backed by a team of technocrats with industry expertise, Orient NexGen delivers solutions tailored to the diverse needs of the print industry.

As an OEM of Orient Web Offset, Orient Nexgen’s Premium News Fountain Solution are formulated to cater to all types of web presses and dampening systems. “Designed with precision and versatility, these solutions ensure optimal performance, delivering print quality across a range of press configurations. Whether it’s traditional or modern dampening systems, our fountain solutions provide superior ink-water balance, reduced waste, and enhanced press efficiency, making them the ideal choice for high-performance printing operations,” says Rakesh Chauhan, director, Orient Nexgen Consumables.

The Premium News Fountain Solution reduces printing costs by improving press efficiency and minimising material wastage. It minimises start-up wastage. It ensures smooth and stable cold and warm start-ups, reducing the time and materials wasted during press setup. It lowers water uptake. Its advanced chemistry reduces water consumption, ensuring better ink-water balance and sharper print quality. It prevents web breakage by maintaining consistent performance. It minimises the risk of web breaks, enhancing operational reliability. It eliminates anti-pilling agents. Its formulation eliminates the need for additional anti-pilling treatments, further simplifying the process and saving costs.

“This solution is tailored to reduce operational troubles in newspaper printing, ensuring consistent results, enhanced productivity, and greater cost efficiency,” Chauhan says.

The company’s manufacturing facility started operations in 2023, and the full range of its products was officially launched on 22 January 2024.

The market
According to Chauhan, the company’s range of printing chemicals is designed to serve the entire printing industry, catering to diverse needs with precision and innovation. “With our Premium News Fountain Solution, we target both domestic and international news publication houses, providing them with reliable, high-performance solutions to enhance their printing efficiency and quality,” he adds.

Chauhan says, as an Indian OEM, the company has a deep understanding of the price-sensitive Indian market. “Our products are crafted with the highest quality standards, rivalling those of multinational brand operating in India,” he says, adding, “With our unique formulations, we develop cost-effective printing chemicals that deliver exceptional performance while helping customers reduce overall production costs. Our 22,000-sqft state-of-the-art manufacturing facility ensures streamlined production, enabling us to maintain competitive pricing and consistent supply. This, in turn, supports our customers in meeting tight deadlines and achieving on-time delivery, making our solutions ideal for the dynamic needs of the Indian printing industry.”

The customers
Chauhan says the Premium News Fountain Solution has a worldwide customer base, with presence in Asian and African countries through its robust dealer network. Domestically, the company is supported by 48 dealers across India, covering most regions. It has partnered with seven international distributors to expand its footprint.

Besides the metro cities, the company also supplied the product to many regional newspapers, showcasing its outreach and commitment to catering to diverse needs. “Our focus on quality and cost effectiveness has made us a trusted partner for both domestic and international customers,”Chauhan says.

He says when choosing printing chemicals, customers both in India and globally, look for a combination of factors that ensure quality, reliability, and cost-effectiveness. One key factor is the trust and experience behind the manufacturer. “With over 75 years of expertise in the web offset printing industry, our customers find confidence in our deep understanding of printing technology, consistent product performance, and commitment to innovation.

This long-standing experience assures them that our solutions are engineered to meet industry standards, while also offering exceptional value for money,” he explains.

The application

The company’s chemicals are designed to address a range of printing challenges, with applications across various sectors, including newspapers, commercial printing, packaging, and specialty printing. “Each customer faces unique printing issues, and we provide tailored solutions to resolve them effectively,” Chauhan says.

The company’s technical support team, available across India, works closely with customers to understand their specific needs and optimise the performance of the chemicals. This hands-on approach ensures that the company can address multiple issues at once, from improving ink-water balance to reduce downtime and wastage.

Chauhan gives an example, explaining, “One of our customers in the newspaper industry successfully used our Premium News Fountain Solution to reduce start-up wastage and improve press uptime during high-demand periods. This not only resulted in smoother production but also led to substantial cost savings and print quality.”

The USP
The key USPs of the Premium News Fountain Solution are:

OEM manufactured quality: As an original equipment manufacturer (OEM), the company ensures that its products are designed and produced with precision, meeting the industry standards for performance and reliability.
Machine-friendly: The solution is formulated to enhance the longevity and efficiency of printing machines, reducing wear and tear, and minimising maintenance costs.
Worker-friendly: The company prioritise the safety and well-being of operators. Its products are designed to be easy to handle and non-hazardous, ensuring a safer working environment.
Environmentally responsible: We are committed to sustainability. Our chemicals are eco-friendly, with reduced volatile organic compounds (VOCs), helping to minimise environmental impact and promote a cleaner, healthier workplace.

Chauhan says one of the standout characteristics of the Premium News Fountain Solution is its versatility and compatibility with various dampening systems. Unlike other manufacturers, who offer different fountain solutions for different dampening systems, the company’s formulation is engineered to work seamlessly with multiple types of dampening systems, including spray dampening systems; turbo dampening systems and brush dampening systems.

“This unique adaptability allows our customers to use a single solution across multiple press setups, simplifying inventory management and ensuring consistent performance,” Chauhan says. “By offering a universal solution, we help customers streamline their operations and reduce the need for multiple specialised chemicals, providing both cost efficiency and operational flexibility.

After-sales services
The company’s technical team provides training to workers, ensuring they are well-versed in the proper use of chemicals for trouble-free printing. “We offer hands-on guidance and troubleshooting support, empowering our team to optimise the use of our products, reduce operational issues, and maintain print quality,” Chauhan says.

Made in India: KnowzzleJet

Rahul Kumar — Fri, 31 Jan 2025 03:58:00

The inkjet web press from Monotech Systems, in association with Pressline India offers print-on-demand possibilities, ensuring that businesses and individuals can meet tight deadlines. So says, Tejinder Singh at Monotech Systems.

The KnowzzleJet is a high-speed inkjet web press designed for large-volume commercial printing, available in roll-to-roll, roll-to-sheet, and roll-to-fold formats to meet a variety of production needs. It offers a print resolution of 1,600-dpi. The machine’s manufacturer, Monotech Systems, started its journey in inkjet solutions in 2010 and since then, the company has been a pioneer in presenting digital solutions in flexible packaging, labels, publications, and security printing, among others.

Tejinder Singh, vice-president, print and packaging solutions at Monotech Systems, says, “Utilising eco-friendly water-based inks, the KnowzzleJet is both cost-efficient and environmentally responsible, making it ideal for a wide range of applications, from books, transactional and trans-promotional, direct mail to newspaper/tabloid printing.”

Launched in 2020, the press is available in both colour and monochrome configurations, providing flexibility for different printing requirements. With a web-fed system, continuous rolls of paper are processed with advanced tension control for smooth handling. It has been conceptualised, designed and jointly developed in India by Monotech Systems and Pressline India.

The advantages
The machine is targeted at digital and commercial printers focusing on the applications like books, direct mail, transactional, trans-promotional, and newspapers.

“This print-on-demand product is suitable for an extremely price-sensitive market like India. The affordability of printing at approximately four paisa per A4 page for monochrome and less than 50 paisa for colour prints makes it an attractive option for digital and commercial printers. Given the low cost, customers can print only what they need, which eliminates the overhead of bulk printing and storage. This significantly reduces waste and upfront costs, making it ideal for those who require low-volume printing without compromising on quality,” Singh says.

He adds that it is also a green technology as the major consumable is the ink which is water-based. So, compared to offset, all other consumables like fount, washes, and plate cleaners are eliminated in this.

He adds, “On-time delivery is another key advantage. As the machine offers print-on-demand, customers can have prints produced and delivered quickly without the long delays often associated with bulk printing. This ensures that businesses and individuals can meet tight deadlines and manage time-sensitive projects efficiently.” Overall, Singh says, the press provides a balance of affordability, flexibility, and speed, making it a great solution for customers in India who are looking to manage print costs while ensuring on-time delivery for their projects.

The market
According to the company, currently there are 10 colour and monochrome KnowzzleJet presses running in India with some of the leading publishing houses like Arihant Publications, Bhavik Publications, Saurabh Printers and YCT Publishing. Singh says while choosing a print-on-demand printing press, customers, both in India and globally, prioritise affordability, print quality, and convenience. In price-sensitive markets like India, the low cost per print is a key driver. Ultimately, customers want a solution that balances low cost, high quality and ease of use, all backed by strong customer support.

Explaining what the press can achieve, Singh gives the example of Greater-Noida-based Saurabh Printers, which successfully printed and exported the Malaysian Civil Procedure Book on 32-gsm Bible paper. Singh says it’s an impressive feat in the realm of inkjet printing, typically considered quite challenging.

The productivity
Singh says the KnowzzleJet is designed for ease of use, even in high-volume, fast-paced print environments. It features an intuitive user-interface that simplifies job setup, allowing operators to easily load print files, adjust specifications (like paper size, colour, and volume), and manage print speeds.

With automated features for paper handling, ink management, and quality control, the system minimises manual intervention and ensures consistent results. Real-time monitoring tools also allow operators to track print quality and make adjustments on the fly, ensuring high efficiency and minimal errors. The press is built for reliability, with maintenance alerts and accessible customer support, making it a streamlined solution for both large and small-scale printing needs.

Singh says Monotech Systems provides comprehensive training for operators of the KnowzzleJet high-speed inkjet web press to ensure they can operate the system efficiently and maintain high-quality output. The training includes basic operations, such as loading print jobs, selecting settings, and using the user interface. It also covers routine maintenance, troubleshooting, and addressing print quality issues, allowing operators to minimise downtime. The advanced training focuses on optimising the machine’s features, such as automated paper handling, print speed adjustments, and workflow integration.

“Additionally, safety protocols, real-time monitoring, and quality control are emphasised to ensure smooth operation. Monotech Systems offers both on-site training during installation and ongoing support, ensuring operators are well-equipped to maximise the press's capabilities and performance,” Singh says.

The support
The company also offers comprehensive service and support for the knowzzleJet. This includes on-site installation and setup, followed by initial training for operators. Ongoing technical support is available through phone, email, and remote diagnostics, while preventive maintenance services help keep the equipment in optimal condition.

Monotech Systems also provides access to genuine spare parts, consumables, and software updates to ensure long-term performance. For more complex issues, on-site support and emergency assistance are available. Additionally, the company offers extended service contracts, warranties, and refresher training to ensure that operators remain up-to-date with new features and best practices.

“This holistic support approach allows businesses to maximise the performance and longevity of their KnowzzleJet press. With our offices and manpower in all major cities across India, we intend to provide services on SOS basis,” Singh says. He concludes, “As per an estimation, the current financial year will have an installation of 30 inkjet web presses in India. Monotech Systems aims to become a market leader in this segment by the next financial year.”

The USP

It is conceptualised, designed, and developed in India. It offers high-speed performance of up to 660-ft/min in monochrome and 200-ft/min in colour. The machine comes with Duralink and Duraflex printheads from Memjet and offers paper handling from 45 to 150-gsm.

The press comes with multiple resolutions, from 580 to 1,600-dpi. Customers can change it depending on the print requirements. For example, if a customer wants to print plain text matter, he can do it on 580-dpi. If he wants bright highlight areas, he can increase it to 790-dpi. If he wants to print high-quality images, he has an option of 1,600-dpi.

The press comes with an unwinder unit, an inkjet printing unit, and a sheeter unit/folding unit.

Made in India: E-Aqua barrier coating from Empowera Technorganics

Rahul Kumar — Tue, 12 Nov 2024 14:41:00

Delhi-based Empowera Technorganics manufactures barrier coatings under the brand name E-Aqua. The current products in this product line include E-Aqua BR 602, E-Aqua PC 701, E-Aqua BR 707, E-Aqua BR OGP and E-Aqua BR OGT, among others. Each product is designed to meet specific barrier performance requirements, such as water resistance, oil and grease resistance, heat and chemical resistance or a combination of these.

According to Nikhil Mahajan, vice-president, Empowera Technorganics, the company’s primary focus is to innovate and deliver high-quality ‘Made in India’ adhesive and coating solutions to its customers. Since its inception, Empowera has been committed to sustainability and technological advancement.

Mahajan says the E-Aqua barrier coating range marks a significant milestone in the company's journey, reflecting its dedication to protecting the environment while delivering excellent performance. “Empowera Technorganics continues to expand its portfolio, focusing on research and development to meet the evolving needs of various industries,” he adds.

The product
Barrier coatings from Empowera Technorganics are based on advanced polymer technology that helps create effective barrier layers. The raw materials are selected carefully and used in combination with various additives to develop a coating system for use in direct food contact. It is 100% recyclable and provides excellent resistance to water, oil, grease, etc.

Barrier coatings are designed to form a hydrophobic and protective layer on paper, enhancing its functionality and durability. This, in turn, makes the paper suitable for a wide range of applications, including food packaging, which was earlier dependent upon plastics.

Empowera Technorganics has been developing these products since 2018. Mahajan says, over the last six years, the company has developed products for different applications. “India has a diverse culture and food habits. Thus, there are distinct requirements from the food packaging industry. We have been working closely with paper manufacturers and converters to address those needs and help packaging companies reduce their dependency on plastics,” he adds.

The market

The E-Aqua barrier coatings are designed for a diverse range of industries. These include food packaging, consumer goods packaging, industrial packaging, and the print and paper industry.

“Our coatings provide water, oil, and grease resistance, ensuring packaging remains intact and clean, making them ideal for manufacturers of food packaging materials, such as fast-food wrappers, bakery boxes, and snack packaging. Additionally, producers of coated paper and paperboard used in various industries also benefit from the enhanced durability and resistance provided by the coatings. Our coatings align with the growing demand for sustainable packaging solutions by offering high-performance protection without compromising eco-friendliness, making them a versatile and cost-effective choice for businesses and brands focused on quality, longevity, and environmental responsibility,” Mahajan explains.

The products contain polymer emulsions made from carefully selected monomers and surfactants with a core-shell process. It also contains additives to enhance coating ease of application, WR and OGR properties, stability and various other requirements.
The industry is currently dominated by extruded polyethene (PE) coating. This is a plastic product which once coated via extrusion is difficult to recycle or re-use. Mahajan says Empowera products are a direct replacement for PE coating but are 100% recyclable as they become a part of paper fibres on re-pulping of paper, thereby reducing overall paper lifecycle costs. “While, currently, PE coating is cheaper, with increasing demand, our coating prices are expected to come down as well. When we look at the overall supply chain, our product offers many more benefits,” he adds.

Mahajan says the E-Aqua barrier coatings have a growing global customer base, spanning various industries, including food packaging, consumer goods packaging, and industrial applications.

“Most of our coatings are being used to manufacture food packaging products exported to Europe and the US. In India, our product is being used by packaging converters for brands such as McDonalds, KFC, etc,” he says.

According to Mahajan, when choosing barrier coatings, customers typically look for high performance, cost-effectiveness and sustainability. “They seek products that provide excellent protection against water, oil, and grease, ensuring durability and extended shelf life. Additionally, compliance with environmental standards is crucial. Our E-Aqua range of products is tested for direct food contact applications as per standards in India, Europe and the US.

The application

The coatings are primarily used in food packaging applications, such as fast-food wrappers, bakery boxes, snack packaging, and other food containers. These coatings provide superior resistance to water, oil, and grease, ensuring the integrity and freshness of the packaged food. The coatings are a replacement for plastics and ensure sustainability while enhancing recyclability and protecting our planet. These coatings are microwave-safe and provide a host of other benefits depending on performance requirements.

The products are currently being used in sweet boxes (to prevent oil from seeping out), burger and food wraps, burger and fries boxes, vomit bags on airplanes, eCommerce courier bags, and others.

“We are working on many more such applications. All these innovations have helped companies reduce plastic usage and appeal to modern-day eco-conscious consumers while setting a new standard in the food packaging industry,” he says.

The USP

According to Mahajan, the benefits of these products include superior barrier protection against water, oil, grease, chemicals, heat, etc; cost-effectiveness; 100% re-pulpability and recyclability. “It is a made-in-India product with local and proactive support,” he says. “We offer customisation options to our customers no matter how big or small they are.”

The E-Aqua range of products offers a variety of properties, including hydrophobicity, oleophobicity, recyclability, and chemical and heat resistance. The products can be designed to be microwave-safe and can be customised. All of these have led to various developments in different industries as detailed in previous examples.

“Our products have evolved over the last six years and they keep on evolving as this market is evolving rapidly. The use of packaging in India, specifically in the food industry is growing very fast and the industry in itself is dynamic. Our products are at the forefront of such innovation,” he says.

The company offers complete guidance starting from choosing the correct product to its proper application as per customer requirements.

“We also offer to go back to the drawing board and develop a completely new solution for our customers if our current range of products does not fulfil their present requirement,” he says and gives the example of a customer who needed a custom barrier coating which did not stick to the cold seal adhesive layer on the other side of the paper in roll form. “This required us to add release properties to our existing barrier coating product as cold seal adhesive can have some residual tack, especially at high-pressure conditions. While working closely with the customer, we developed a special release barrier coating for the customer which fulfilled all their performance requirements.”

He concludes, “We see a healthy shift from single-use plastics and an increased focus on paper for consumer packaging needs. Further, there is an increasing trend towards recyclability, driven by environmentally conscious Indian consumers.”

Made in India: IEEC: How to convert ozone to oxygen

Rahul Kumar — Wed, 23 Oct 2024 10:40:00

IEEC Power Electronics, which specialises in corona treatment systems, plasma generators, ozone generators, and destructors, has been a key player in power electronics and industrial equipment manufacturing since 1969. Since its inception, IEEC Power Electronics has been manufacturing corona treatment systems, used in surface treatment processes in the converting, packaging and printing industries. These systems utilise high-voltage electrical discharges (corona discharge) to modify the surface properties of materials, enhancing their adhesion characteristics for better printing, coating, and bonding. In addition, IEEC has expanded its expertise into plasma technology. Its plasma generators are used in a variety of industrial applications for surface cleaning, etching and activation. IEEC also manufactures ozone generators for converting industries. In the extrusion coating process, a film is treated with a corona treatment system, but to improve adhesion, the melt is treated with ozone. IEEC's ozone generators produce ozone in precise concentrations needed for these applications, ensuring efficiency in treatment.

Ozonash ozone destructors
IEEC manufactures ozone destructors used in the converting, packaging and plastics industries. Ozone is a byproduct of the corona-treater, which can be harmful to the environment if released without proper treatment. IEEC’s ozone destructors neutralise ozone by converting it back into oxygen. “Over the decades, IEEC has maintained a reputation for innovation, reliability, and quality, serving a diverse range of industries with its specialised equipment. Its commitment to technological advancement has allowed the company to stay at the forefront of surface treatment systems,” Rohit Deshpande, director, IEEC Power Electronics, says. The technology of IEEC's Ozonash is a device that neutralises ozone by converting it back into oxygen.

Ozone is a disinfectant and oxidiser; it is also unstable and can be harmful to both the environment and human health in high concentrations. Ozone destructors are, therefore, essential in ensuring that ozone is safely broken down into its components — oxygen (O2) — before it is released into the environment.

Deshpande says the basic technology behind an ozone destructor is the use of a catalytic process to break down ozone. These processes involve converting ozone molecules (O3) into oxygen molecules (O2) in a controlled manner, eliminating the risk of ozone pollution.

In the process, the ozone enters the destruction system, where a combination of catalysts efficiently converts it to oxygen.

This process occurs at room temperature, thanks to specially designed catalyst granules containing precious metals. No external energy is required to initiate the reaction. The catalyst provides a surface for the ozone molecules to react with, causing them to break apart and form O2 and O [O3 -> O2 + O (oxygen atom)]. In the next step, the oxygen atom reacts with another ozone molecule to form two molecules of oxygen (O + O3 -> 2 O2).

In summary, the ozone destruction system plays a crucial role in controlling ozone pollution and ensuring the safety of the workplace. It also increases the life of the components of the treating station and machines. According to Deshpande, the multi-stage catalytic destruction system Ozonash consists of a pre-filter with filtration of up to 5ų to avoid contamination of the catalyst; a HEPA filter to remove at least 99.97% of dust and other foreign particles up to the size of 0.3ų; activated ceramic beads act as a desiccant and reduce contamination of harmful functional groups with the catalyst; and a bed of metal oxide catalyst granules. “By implementing the Ozonash system, companies can ensure compliance with ozone limits, enjoy cost savings through catalyst regeneration, and maintain a durable infrastructure by utilising suitable materials,” Deshpande says.

The market
Ozonash is aimed at any industry or organisation that generates or uses ozone, whether in industrial production, water treatment, air purification, food processing, or medical applications. The primary goal is to ensure safety, compliance with environmental regulations, and the prevention of ozone related health risks for both workers and the broader environment.

Deshpande says the company’s ozone destructor is suitable for a price-sensitive market like India due to its energy efficiency and regulatory compliance. “It reduces the maintenance cost and increases the life of the treating station and the machine,” he says, adding, “Its minimal maintenance requirements cut down on long-term costs while ensuring compliance with environmental regulations prevents potential fines. With timely delivery and the ability to customise based on local needs, the ozone destructor ensures both cost-effectiveness and efficiency, making it a valuable solution for industries looking to optimise operations while maintaining safety and compliance.”

Deshpande says in both India and globally, customers prioritise regulatory compliance, system efficiency, cost-effectiveness, and environmental impact when choosing an ozone destruction system. “Technological innovation, ease of maintenance, and scalability are also critical considerations, especially as industries face evolving environmental challenges and regulations. Therefore, choosing the right system involves balancing performance, cost, sustainability, and support factors to meet both immediate needs and long-term goals,” he adds.

The productivity
Productivity is a critical factor when evaluating the performance and value of an Ozonash. It refers to the system’s ability to handle ozone efficiently and deliver results with minimal downtime, energy consumption, and labour. Deshpande says Ozonash processes large quantities of ozone-depleting substances quickly. The system is designed for continuous operation without frequent downtime or manual intervention, significantly boosting productivity. “Reliability and longevity of catalyst chamber are the key components that contribute to reduced downtime and higher productivity,” he adds.

He says the system is easy to use. “First, attach the duct to the input of the Ozonash system. Ensure that the blower is connected to a three-phase power supply. Once these connections are made, the Ozonash system should be ready to operate,” he explains. IEEC provides on-site or remote guidance during initial installation. It also offers troubleshooting assistance for operational issues. Service support is also available through the service centres located in the metro cities.

The target
Deshpande says the company received an overwhelming response at Labelexpo India 2024 held in November. “A key concern raised by visitors and label manufacturers was the challenge of managing outlet ducting for ozone extraction outside the premises. Additionally, numerous visitors highlighted complaints about ozone odour affecting the neighbouring industries and frequent issues with duct maintenance and machine upkeep,” he says, adding that Ozonash offers the perfect solution to these challenges.

He adds, “Its innovative design eliminates the need for complex outlet ducting, minimises maintenance requirements, and ensures efficient ozone management.”

Made in India: Adhesives from Astra Chemtech

Rahul Kumar — Tue, 30 Apr 2024 17:19:25

In recent years, Astra Chemtech has captured the attention of the market with innovative excellence combined with a fierce commitment to sustainability. Founded in 2000 as a private limited company, Astra Chemtech later transitioned into a manufacturing powerhouse with a vision to redefine the standards in the printing and packaging sector. Through calculated risks to innovate new products, use of state-of-the-art technology to bring in international quality products, and able leadership and foreseeing the dynamic duo of Rashid Sorathiya and Farid Sorathiya, the company embarked on a transformative journey, supported by its commitment to innovation and customer satisfaction.

From trading to manufacturing
Astra Chemtech began with a clear vision to establish its brand identity in the adhesive segment. With a strategic move towards manufacturing in its early days, the company built its primary expertise in water-based lamination adhesives.

Shekhar Mhapsekar, director of marketing, Astra Chemtech, said, “The industry respect we earned in the process laid the foundation for our future growth and success. Urged by our continuous push for excellence, we quickly gained recognition for our quality products and unwavering commitment to quality. Attaching immense value to customer satisfaction paved the way for the rocket-like push they gained as they grew.”
Then, the company went all guns firing to rapidly pivot its portfolio with a diverse range of segments toward pressure-sensitive adhesives to cater to the label industry. As it surged ahead, Astra held onto its quality. To bring additional push and expand its brand respect further in the book-binding and soap wrapper industry, Astra added hotmelt adhesives to the portfolio.

Today, its flagship products, water-based TS 600 and hotmelt pressure-sensitive TM9600D, prove the company’s push towards quality. Further to the hotmelt segment, pasting adhesive TPW 100 is its new product, which is a market leader in its segment.

Products for packaging
Astra Chemtech has two flagship products for the packaging segment – Turbocryl TC-177, Turbopower TPW-100 and Turbomelt TM-9600 D.

The Turbocryl TC-177 is a high-performance lamination adhesive offering several advantages, such as high solid percentage formulation; exceptional bonding for a variety of films, including PVC, polyester, MetPET, and= BOPPl; addresses ink defects, ensuring flawless print quality and delivering outstanding yield value, optimising cost-effectiveness

The Turbopower TPW-100 is a side-pasting adhesive for cartons, boasting features, such as high solid percentage formulation, ensuring robust performance; ideal for sensitive substrates with low energy levels; suitable for high-speed machines, enhancing productivity; provides superior bond strength, ensuring packaging integrity; and environmentally friendly water-based formulation, aligning with sustainable practices.
The Turbomelt TM-9600 D is a hotmelt pressure-sensitive adhesive for stock label applications. The highlights include high peel strength; high shear strength; good die cutability and suitability for low surface energy substrates.

Aim to be a powerhouse
Now, Astra Chemtech is aiming to be a global powerhouse. And the stepping stone to that ambition is to reach a revenue of Rs 1000-crore and to offer end-to-end, comprehensive packaging solutions.
“Astra Chemtech has set an assertive goal for itself to provide end-to-end solutions for almost all industries, to be a single-point international hub. No doubt, in the process we will redefine industry benchmarks and also emerge as a leader in a global market,” Mhapsekar says.

As its customers’ needs expanded, Astra Chemtech expanded its horizons beyond adhesives into inks and coatings. This calculated, strategic move marked a significant milestone in the company's journey, positioning it as a formidable competitor in the domestic as well as the global market. The company turned pages, heads and a corner with its introduction of UV inks and coatings three years ago. This turning point propelled Astra Chemtech into the league of multinational companies.

In its long journey, Astra Chemtech has taken risks, calculated and ambitious ones. And all of them have yielded astronomical results. These risks, taken to position the company in the top echelons of the international players, were driven by the ambitions of the Sorathiya brothers.

In its next move, Astra Chemtech is undergoing a complete transformation. Sustainable innovation is the cornerstone of their new strategy, as they aggressively expand their product offerings to meet evolving market needs.
Mhapsekar says, “From synthetic adhesives for woodworking to UV coatings for specialised applications, Astra Chemtech has continuously expanded its portfolio to encompass a wide range of solutions. Furthermore, Astra Chemtech continues to explore new frontiers in UV coatings and inks, including LED inks for offset processes and heat seal lacquer with oil and grease resistance (OGR).”

Research and Development Excellence
Astra’s research and development centres are dedicated to uncovering the perfect chemistry, bringing in the latest innovations in technology and inventing groundbreaking processes.

Mhapsekar says, “Our comprehensive global R&D efforts encompass an array of activities, from fundamental laboratory investigations to pioneering advancements in ink dispersant technology. We delve into ink-and-media compatibility testing, jetting assessments, system software design, print head innovations, and beyond. Our commitment lies in crafting solutions that enhance efficiency, reduce operational costs, unlock new revenue streams, and contribute to a sustainable future. We excel in tailoring solutions to meet the unique requirements of each customer, while continuously introducing fresh concepts and the latest technological breakthroughs to the market, spanning ink, coatings, and adhesives.”

Astra Chemtech actively participates in the Make in India initiative, aligning with the government's vision to promote domestic manufacturing and propel India’s growth as a global manufacturing hub. By manufacturing high-quality packaging solutions locally, Astra Chemtech contributes to the country’s economic development and reinforces its commitment to serving the Indian market.

Astra Chemtech's production plant in Boisar, Palghar, Maharashtra

Looking ahead
Innovation is the heart of Astra Chemtech’s growth and expansion. With a focus on research and development, the company continuously explores new technologies and formulations to not only stay ahead of the curve but often curve the path itself. By investing in facilities and a talented team of professionals, Astra Chemtech ensures that its products meet the highest standards of quality and performance.

The success of Astra Chemtech's products can be attributed to their unique combination of performance, reliability, and sustainability. By prioritising eco-friendly formulations and production processes, the company not only reduces its environmental footprint but also meets the growing demand for sustainable solutions in the printing and packaging industry.

With a clear vision for the future and a determination to succeed, the company is poised to shape the future of the printing and packaging industry, redefining standards and setting new benchmarks for excellence.

Astra Chemtech will be located at Stand B22 in Hall 3 during the Drupa exhibition.

Made in India: Arobond 64 water-based pasting adhesive for folder-gluers

Rahul Kumar — Sun, 31 Mar 2024 09:27:00

The Arobond 64 from Arofine Polymers is used as a side-seam pasting adhesive in the manufacturing of mono cartons on folder-gluer machines. The Arobond 64 is applied through a roller/disc application and due to its fast-drying nature offers bonding properties even when the machine is on a high speed.

Arofine Polymers started its operation in a garage in Pune in 1976. Over fifty years, the group has earned a reputation as an ethical, quality-conscious manufacturer of industrial adhesives and coatings.

The product: The Arobond 64
Launched in 2015, the product is aimed at all printing and packaging companies engaged in the manufacturing of cartons.

Chaitanya Joshi, business manager (domestic and export), Arofine Polymers, says, “The Arobond 64 has been designed and manufactured keeping in mind quality and consistency of the product as the key attributes rather than price, as pasting adhesive is the most crucial factor in the overall performance of the cartons. A failure of side-pasting adhesive can lead to serious losses.”

He adds that the cost-effectiveness of the Arobond 64 is derived from fewer rejections and the quality issues a customer might face while using the product.

“The Arobond 64 has been designed to handle multiple end-use applications, such as side-seam pasting of mono cartons, window-pasting, and board-to-board pasting, thereby reducing inventory levels,” Joshi says.

The USP
Joshi says while investing in such a product, customers usually look for consistent performance on various kinds of board substrates, compatibility with old conventional pasting machines as well as new high-speed machines.

The Arobond 64 is produced at Arofine Polymers’ unit and is designed to offer consistent quality for all product batches.

The USP of the product is also its compliance to regulatory requirements like RoHS and REACH, adaptability on different pasting machines, and the resistance that it offers at a wide temperature range.

Joshi says the Arobond 64, with its versatility and aggressive pricing, is a one-stop solution for most pasting needs of a printing and packaging customer.

“Conventional high-speed pasting adhesives are often more expensive than other regular pasting products and thus, converters end up carrying separate inventories for all their pasting needs. With Arobond 64, converters can consume it at lower release for low-cost jobs,” Joshi explains. “Due to the fast-grab and flow characteristics, Arobond 64 spreads and penetrates the pulp surface forming a strong bond on drying. The product can run on all conventional and high-speed pasting machines. It is easily cleanable and operator-friendly. Once dry, the polymeric chains have good chemical resistance, making it suitable for packaging of a variety of ingredients.”

The productivity
Joshi says the Arobond 64 is designed to work on all leading folder-gluers at high speeds of about 400-m/min, thereby ensuring high productivity.

“The Arobond 64 is better in terms of high-speed machine runnability and chemical resistance as compared to its previous version,” he adds.

The product is shipped in ready-to-use form and is easy to use on a folder-gluer. One needs to follow the processes of the Arobond 64 technical data sheetfor the correct utilisation of adhesive. No special training is required for using the adhesive.

Joshi explains, “The Arobond 64 is a multi-use adhesive. One of our customers uses Arobond 64 for cartons exposed to low-temperature or deep freeze applications as it offers bonding strength even in these challenging conditions.”

Best practices
Joshi says unlike earlier, today customers refer to the technical data sheet and train their staff for the proper use of adhesives. “We find detailed SOPs displayed on the machines with regards to adhesive use,” he adds.

Regarding the recent trends in packaging and printing, he says, “We feel in the coming years, functional coatings such as OGR coatings and heat-sealable coatings would find more use in the mainstream applications, such as ice-cream cartons, food packaging, among others.”

In the current fiscal, the company plans on being among the top three suppliers for this specific grade of adhesive, Joshi concludes.

Product specifications

Product name: Arobond 64
Product Type: Pasting adhesive
Appearance: Milky white emulsion
pH: 5.0-7.0
Film: Clear film
Method of application: High-speed machine, wheel application
Suitable for: BOPP, PET, MetPET laminated, unlaminated and aqueous-coated
Standard Packing: 50-kg carboy; 20-kg bucket; 4x5-kg plastic bucket packed in a corrugated box
Shelf life: Six months from the month of manufacturing
Storage: Store in a cool and dry place away from heat and direct sunlight

Made in India: Daya fully automatic film laminator model Jazz

Rahul Kumar — Thu, 15 Feb 2024 12:15:00

Daya fully automatic film laminator model Jazz with sheet separator and stacker is equipped with offset-type auto feeder with four lifting and four forwarding suckers which can take stock from 120-450gsm. The feeder timing is servo-controlled for precise overlap of sheets. The feeding table has a vacuum suction, specially designed for lower grammages of sheets. Lamination-nipping is controlled by motorised hydraulic pressure, coupled with a mirror glass-finished steel roller and silicon pressure roller. The adhesive dispensing is done by a diaphragm pump for continuous flow of adhesive. The film unwinding and rewinding is on airshafts with pneumatic brakes and auto-rewind motorised tension controls. Laminated sheets with BOPP film are auto-cut in collected on the stacker. The structure on 25-mm plate makes it strong and sturdy for high-speed production.

Founded in 1963 with types and fonts to letterpress treadle machines to today’s digital era, Daya has always been a leader in innovation, marching ahead of time with quality products, and providing the right solutions for the post-press, packaging and paper converting industry. With footprints in 50+ countries worldwide, the company proudly flags Made in India products with international standards of quality and safety, earning customer’s loyalty with performance and efficient service.

The machine
According to Neeraj Sheth of Daya Printograph, the Daya Jazz automatic lamination machine is capable of laminating BOPP, metPET, plain PET, matt, gloss, structured, or special effects films to printed / non-printed sheets with exceptional high bond and peel strength.

“With precise overlap controlled with servo ensures accurate positioning of each sheet thereby reducing wastages and saving huge costs in paper, film and adhesive. The machine is designed with unparalleled precision and efficiency for post-press operations with speeds up to 60-mpm. The machine can laminate all kinds of films with water-based adhesive and/or thermal film,” Sheth adds.

The latest model was the machine was launched in May 2022. The machine is aimed at all packaging companies, commercial printers, book printers and also for digital printers with a variant. It is suitable for medium to large-scale in-house printers as well as for job workers.

The customers
“This product is ideal for customers who are already using two or three hand-feed machines and working 10-12-hour shifts daily and want to automate/upgrade their existing processes. Jazz offers a complete solution for anyone who is facing labour issues, missing delivery timelines, and losses in productivity and quality,” Sheth says.

The key customers who are using the machine include Light Publication, Vadodara; SRM, Chennai; Print Hub, Rajkot; Upkar Print House, Agra; Swapna Printing, Kolkata; Vibgyor Arts, Kolkata; and Balaji Printers, Bengaluru.

Sheth says customers opt for this product to automate the lamination process which otherwise poses a bottleneck for the entire printing and packaging process. “Higher productivity, consistent quality and reduced wastages are the key factors to opt for the automatic lamination machine,” he adds.

The typical application of the machine is for cartons, luxury packaging, personalised packaging, gift boxes, stationery, book covers, calendars, wedding cards, invitations, brochures, menu cards, commercial jobs, photo books, and high-end bespoke prints. “Many customers are using our machine for holographic customised film lamination on book covers as a security tool. Another segment uses our lamination machine for digital print enhancement for foiling,” Sheth explains.

The USP
According to Sheth, the auto feeding with servo-controlled precise overlap, pre-loader as optional, heavy-duty motorised hydraulic pressure, adhesive dispensing pump, pneumatically controlled coating nip, separate motor for glueing rollers, and auto rewind tension control make this machine a one-man operation with speeds up to 60-mpm. It can take stock range from 120- to 450-gsm. Powder cleaning devices, thermal lamination, foiling attachments, and inline embossing/texture are also available in upgraded model.

“This is an ideal solution for customers between a hand-feed machine and a fully automatic high-investment machine. Customers get the best of both worlds — medium investment and higher productivity with automation,” Sheth says.

She adds, “The new version ensures precise overlap controlled with servo giving accurate positioning of each sheet, thereby reducing wastages and saving huge costs in paper, film and adhesive. The machine is designed with unparalleled precision and efficiency for post-press operations with speeds up to 60-mpm. Auto sheeting helps improve productivity.”

The machine operation is user-friendly; it’s a one-man operation. “We provide complete installation, operational and maintenance training to the operator. Be it a fresher or a skilled operator, our team provides complete support for training and after-sales service,” Sheth says.

She adds, “This advanced lamination machine optimises production timeline, reduces wastages, delivers precise jobs, ensures impeccable quality and sets new standards for excellence.”

Made in India: Range of slitter-rewinders from SP Ultraflex

Rahul Kumar — Wed, 31 Jan 2024 15:56:00

Founded in 1985, Mumbai-based SP Ultraflex Systems has put to good use its nearly four decades of experience by establishing itself as a trendsetter and innovator in the field of slitting and rewinding, with the widest range of converting slitter rewinders globally.

SP Ultraflex offers a range of nine models of converting slitter rewinders, which are grouped into four series. The compact Primaslit series and the Ultraslit series comes with a separate unwind section, while the Roboslit series of dual turret slitter-rewinders and the fully loaded Roboslit Plus series, differ in their layouts, diameter handling capacities, automation levels and material handling possibilities. The machines have speeds ranging from 600m/min to 1000m/min. "Each model comes with a variety of optional features, allowing SP to offer customised solutions with attention to detail, informs Biku Kohli of SP Ultraflex.

Compact-slitter rewinders
SP Ultraflex offers compact slitter rewinders in two layouts: the Primaslit FL with a front-loading unwind and the Primaslit RL with a rear-loading unwind.

Running at a speed of up to 600-m/min, the Primaslit FL has both unwind and rewind sections on the same (front) end, thus making the area for reel loading and unloading common. According to Biku Kohli, this machine offers greater web threading convenience compared to conventional two-sided machines. The unique layout also limits the need for operator movement, allowing him to monitor the entire process from the front of the machine.

The Primaslit RL (Rear Loading) duplex slitter rewinder is the eternal workhorse of the industry. Positioning the unwind at the rear end allows bigger diameters at both the unwind and rewind. This machine runs at a speed of up to 600 m/min and can be upgraded with advanced material handling mechanisms at both the unwind and rewind.

Sliter-rewinders with a separate unwind
The Ultraslit series of duplex slitter-rewinders has the unique feature of separating their unwind sections from the main machine. This design allows the operator to have free access to the cutter. These machines can operate at a speed of up to 700 meters per minute and are available in two possible layouts - the Ultraslit OHP with an overhead path and the Ultraslit FSU with an underpass working platform.

The Ultraslit OHP (overhead path) duplex slitter-rewinder has an overhead bridge that transports the substrate from the unwind section to the main machine. This design eliminates the possibility of contamination by floor dust, making it an ideal choice for those serving the food and pharmaceutical sectors. Additionally, this layout offers easier web passage, better all-around access, and good visibility of key areas.

The Ultraslit FSU (free-standing unwind) duplex slitter-rewinder has a working platform between the unwind section and the main machine, effectively dividing the machine into two parts, both easily visible and accessible. This version is sometimes preferred for surface printed jobs, where web monitoring and splicing at the unwind are crucial to the application.

Fully automated sliter-rewinders
The Roboslit Plus series consists of advanced versions of the Roboslit series of dual turret slitter rewinders. These machines can run up to 1,000 meters per minute and effectively address the productivity bottleneck of converting slitters after finished reels changeover, known as job changeover.

The fully automatic job setup feature of these machines pre-aligns the unwind, cutting and rewind sections, allowing the machine to slit in register with minimum passage of material. The web guide sensor at the unwind is pre-aligned by means of a servo motor to define the target position of the tracker tone line in the package design. Servo-driven pick and place mechanisms for both cutters (top and bottom) move them simultaneously to successive cutting points corresponding to the package design. Finally, servo-driven pick and place mechanisms provided on each shaft move the empty cores on both shafts simultaneously and position them at their respective positions corresponding to the package design.

The Roboslit Plus series comes with several upgrades over the Roboslit series including a vacuum splice table at the unwind for registered joints, a secondary pusher for unloading rewind reels from the off-loader onto a conveyor belt, a servo-driven horizontal carriage for the lay-on assembly, an area scanner at the rewind end, a SCADA working environment, CCTV surveillance of key areas, and a static level monitoring system.

The Roboslit Plus series consists of two models - the Roboslit Plus OHP (overhead path) dual turret slitter rewinder, which offers high productivity within a hygienic environment free from contamination, and the Roboslit Plus FSU (free-standing unwind) dual turret slitter rewinder, which is sometimes preferred for surface printed jobs due to the enhanced visibility it affords.

The vision
Kohli says his company's mission is to offer the converting industry a perfect combination of reliability and affordability. By doing so, it aims to enable its customers to achieve a better value proposition compared to higher and lower-priced alternatives.

"Our goal is to maintain customer loyalty and market leadership. Additionally, we aspire to establish an efficient work culture while remaining dedicated to their customers, employees, and other stakeholders," Kohli says.

He adds, "Our company's core strength lies in continuous improvement and innovation. We take the lead in introducing new concepts and technology to enhance performance, automation levels, and productivity. This is achieved by increasing process speeds and reducing changeover times."

The customers
Kohli says the company’s customers comprise converting companies that produce flexible packaging laminates and supply them to brand owners in the food, hygiene and pharmaceutical sectors. It includes some of the most reputed converters for whom the selection of capital equipment is an elaborate process of due diligence and comparison between the various options available before selecting the option that offers the most value for their money. A few prominent names include Huhtamaki, SB-Constantia, Paharpur, TCPL, Shrinath and GLS.

The USPs
Kohli says that while each model has its set of USPs, the common focus areas across our range include productivity, reliability, user-friendliness, quality of output and long life.

“Our machines provide the best value for money. Although our machines are priced higher than the competition in India, the difference takes but a few months to recover, considering the USPs, he says, adding, “We realise that after-sales service can only be as good as the skill and knowledge of the service team and as such, we pay much attention to training the team. Considering that most of our sales are repeat business, we consider our service department an extended arm of our sales team. As our customers often vouch, our service standards, in terms of responsiveness and effectiveness, make us stand apart from the competition.”

Made in India: VioGreen chem-free violet CTP plates from TechNova

Rahul Kumar — Thu, 30 Nov 2023 15:10:00

In a world increasingly attuned to environmental consciousness, companies are recognising the importance of crafting holistic experiences aligning with sustainability and customer requirements. TechNova has risen to this challenge by offering the TechNova E.D.G.E. (an initiative that encapsulates Excellence in all business processes; Digital solutions that propel automation, precision, and seamless workflows; Green solutions fostering sustainable goals; and the Ecosystem of consumables, equipment, software and services).

According to Amit Khurana, deputy CEO, offset and digital print solutions, TechNova Imaging Systems, this transformative approach surpasses the realm of products and services, ushering in an unprecedented level of customer engagement.

He adds, “A longstanding partnership of over 50 years between TechNova and the Indian printing industry forms the bedrock of the TechNova E.D.G.E.. As the industry grapples with evolving challenges, TechNova stands resolute as a local manufacturer with a global perspective, delivering tailor-made solutions that address the distinctive demands of the Indian printing industry.”

Dedicated to sustainability
The TechNova E.D.G.E. offers an array of innovations and enhancements across its spectrum, ensuring an ongoing evolution of the customer experience.

This dedication to sustainability is palpable through its unveiling of the next-generation chemistry-free violet CTP plates designed for extra-long runs. These plates seamlessly integrate with various printing machines and newsprints while remaining compatible with both conventional and UV inks.

Expanding this eco-conscious array is the introduction of the thermal process-less CTP plate Kratos, a clean, lean and green solution streamlining the printing process and minimising environmental impact, Khurana says.

He adds that in close collaboration with customers, TechNova extends the life cycle of violet plate-setters through specially designed life extension kits, guaranteeing optimal performance and longevity. Moreover, TechNova offers an extensive range of violet engines from Eco3 and Krause, serving as replacements for end-of-life (EOL) devices.

Workflow brilliance and software precision
Automation workflows introduced by TechNova enhance efficiency, while software solutions elevate print quality. A prime example is the innovative Spiral screening, boosting print sharpness. Meanwhile, soft proofing software simulates press and substrate properties on-screen, ensuring precision throughout the printing process.
“Going beyond tangible products, the TechNova E.D.G.E. encompasses value-added services. A digitised supply chain empowers customers to track ordered materials in real time. The vendor-managed inventory (VMI) for large accounts ensures that the plates are available just in time, significantly reducing inventory carrying costs,” Khurana said. “TechNova’s commitment to environmental stewardship is underscored by its eco-technology-based effluent treatment plants (ETP) and solvent treatment plants (STP). Moreover, TechNova is on the cusp of introducing contemporary tools to measure and reduce overall carbon footprints, cementing its dedication to sustainable practices.

TechNova’s dedication to the Indian printing industry also shines through its advisory services, offering audits, training and consultancy in safety, health, environment and energy conservation.

Adapting to changing consumption patterns
“The adaptability of the TechNova E.D.G.E. to dynamic consumption trends is evident through solutions like the next-generation chemistry-free violet plate for extended runs, green founts and washes, and screening software. These solutions seamlessly adapt to ever-changing customer needs” Khurana explains.

The TechNova E.D.G.E. seamlessly melds with digitised supply chains, presenting offerings, such as VMI and forthcoming carbon audit tools. These enhancements not only elevate the supplier experience but also underscore TechNova’s dedication to a comprehensive printing ecosystem.

A hallmark of TechNova’s dedication to sustainability is its unwavering focus on green products within the E.D.G.E. framework.

A prime illustration is the VioGreen Plus, chemistry-free violet CTP plates. These plates hold immense significance for the Indian newspaper industry's ecological journey, drastically reducing carbon footprints by eliminating water usage, curtailing chemical effluents and facilitating energy and maintenance cost savings.

Since the adoption of VioGreen Plus plates in 2014, the Indian newspaper industry has achieved remarkable milestones. Over nine years, 192-million litres of water have been saved, with an annual average of 27.33-million litres. Chemical effluents have been curtailed by 15.36-lakh litres in nine years, with an ongoing annual reduction of 2.19-lakh litres. Energy and maintenance costs amounting to Rs 23-crore have been saved over nine years, with an annual conservation of Rs 3.30-crore.

Khurana says, TechNova E.D.G.E. stands as an extraordinary example of how a company can elevate the customer experience. “It’s not confined to products alone; rather, it embodies a comprehensive transformation underpinned by excellence, digital prowess, green consciousness and an integrated ecosystem. Through an unwavering focus on sustainability, efficiency and innovation, TechNova has etched an indomitable E.D.G.E., harmonising perfectly with the challenging needs of the Indian printing industry and the broader global impetus towards a greener horizon."

He adds, "TechNova's commitment to customer-first engagement radiates through the multifaceted brilliance of the E.D.G.E., setting new benchmarks for the future of the printing industry."

Customer testimonials
We use TechNova’s VioGreen plates in all of our major printing centres. They are more ecologically friendly, use less water, and require less maintenance. Consequently, we address the issue of sustainability while simultaneously saving money. This, I believe, is the way ahead for the newspaper industry.
Snehasis Roy,
The Times of India

We were among the first newspapers to start using TechNova's VioGreen Plus plates. Now, these plates are used at 90% of our 51 print locations. These plates have helped us save water and energy and cut chemical discharge. The need of the hour is to focus on green and environmentally friendly printing technologies like the VioGreen plates.
Dinesh Sharma,
Dainik Bhaskar

TechNova has been a wonderful partner for the newspaper industry over so many years. They have initiated so many projects to address the issue of environmental pollution and VioGreen Plus plates are one of them. These plates help newspapers cut chemical discharge and save costs.
Bhasi PT,
Mathrubhumi

We began using the VioGreen Plus plates about four years ago and are very happy with the performance. They are being used at all our print locations. We have also started trialing the latest version of VioGreen plates at one of our locations.
Somnath Guha,
ABP

Made in India: Offline drip-off technology from Alpna

Rahul Kumar — Tue, 31 Oct 2023 15:28:00

Alpna has been at the forefront of innovation and high-end technologies in the field of UV curing and coating technologies.

Offline drip-off technology is quite unique to India. Alpna have been pioneers in 2007 when only online options were available. The game-changer innovation from Alpna has helped all the mid to large folded carton converters adopt the drip-off coating system.
“We helped drip-off technology to become popular and accepted by all print buyers from FMCG, pharma, beverages, hosiery, and other segments,” Debashish Dutta, general manager, Alpna Visual Packaging Aids, says.

The product
The company’s product range includes the Rhino-Dexa multi-deck offline coater; offline smart coat drip-off kit with CDB anilox; M-Cure mercury UV System and L-Cure LED UV System.

Dutta says the CDB anilox uses advanced technologies with CDB chambers from Tresu, Denmark. The technology also uses the servo precision sync technology, which is an automatic varnish circulator, and synchronisation with the offset platform of the conveyorisd system. The products come with superior lamp-head and reflector design. The products offer EPS and PLC-based operations for energy efficiency. The machines have detailed engineering designs, taking into consideration shopfloor pain areas, and focusing on productivity and safety aspects.

The Rhino-Dexa and the smart drip-off kit offer one-stop solutions to any kind of offline coating, such as gloss UV coating; matt/gloss UV coating for spot coating; drip-off coating available with different texture options; water-based gloss and matt coating; water-based primer coating; velvet-touch coating; blister medium coating for blister packs and barrier coating for food packaging.

The market growth: From 2009 to now
The Alpna offline drip-off solution started in 2009 while Rhino-Dexa was launched at PrintPack 2015.

Dutta says the product is targeted at folding carton converters and commercial printers. “It is ideal for jobs where a unique and eye-catching finish is critical for branding, aesthetics, and for fighting counterfeiting,” he says.

He adds, “Alpna offers indigenously developed technology that ensures high efficiency and rugged performance. We probably offer the highest price-to-performance ratio for our customers. The use of quality input material, detailed engineering, and unique safety features make our equipment energy-efficient and ensure higher output.”

Alpna has a sales network in more than 11 countries with more than 2,500 satisfied customers in India and across the world.

Some of the company’s existing customers in India include Parksons Packaging; ITC; Noble Print n Pack; Temple Packaging; HBD Packaging; Lynx; Replika; Param Packaging; KCL; Sai Packaging; Printmann; Sneh Comprint; NK Gossain; ST Reddiar; Rajhans; RT Graphics; Fortuner Packaging; Niyogi Offset; Afaraz Healthcare, among others.
Overseas, the company’s products are being used at Silverpoint, Sharjah; Constanta, Moscow; Inter Pack, Bangladesh; GTC Converters; Sri Lanka; Padma Lamitube, Dhaka; Prepaid Solution, Ghana; Sama Printers, Nepal; Sarl Img, Montanari, France; Afra Asianray Printing Equipment Trading LLC, UAE; Archie Offset Printer, Kathmandu; Atlas Axillia, Sri Lanka; Jerusalem Digital Printing Co, Jordan; Shokoh Noor Khorasan Food Ind, Tehran, among others.

LED UV systems to prosper
Debashish Dutta says while choosing such a technology, customers usually look for the latest technology, reliable efficient performance, high productivity, energy efficient systems for cost-saving and sustainability.

“We are popular among packaging converters for our ability to offer customised solutions for various applications and different offset presses. This is possible because of our strong engineering team and our deep understanding of the technology platforms,” he says.

Dutta says Alpna’s EPS-based conveyorised systems and inter-deck systems have replaced the traditional transformer-based systems. These clinically designed EPS systems offer a host of benefits to consumers, such as lamp output control leading to power-saving and increased efficiency; increased production safety; accuracy in printing leading to superior print quality and virtually maintenance-free operation.

At the same time, one of Alpna’s USPs is an extremely good price-to-quality ratio.

Dutta adds, “We are engaged in continuous innovations and upgradations of our products which are based on customer feedback, continuous innovations, and focus on energy efficiency and safety of machines and users.”

He explains that Alpna equipment are user-friendly and are designed with highest level of safety features. “This has been our forte from the very beginning and we never compromised on this,” Dutta says. “We are engaged in continuous training of end users. The training is imparted by our trained service engineers. We have pan-India service and application support. We have trained engineers stationed in all major cities in India. Other locations are covered by these regional hubs.”

According to Dutta, India’s position and image in the global landscape have changed, and technology and solutions from India are taken seriously as compared to what it was in yesteryears. Today, Alpna wants to expand its footprint across the globe, and Dutta says the company has a huge opportunity in front of it.

“Higher productivity and minimalistic design will be a trend in the future. LED UV systems will come in a big way in the coming years due to the associated benefits attached to them. Growth in eCommerce will change the landscape of packaging demand and design in a big way,” he explains.n

Made in India: Drip-off solutions from Autoprint Machinery

Rahul Kumar — Mon, 25 Sep 2023 14:02:00

For years, lamination has been used to protect the printed material and to enhance print value. However, there has been increasing concern over the environmental impact of traditional lamination methods. The durability of lamination has also been questioned. Addressing both these issues effectively while enhancing the visual appeal of the printed material,

Autoprint has introduced an offline dedicated high-tech drip-off coating machine.

The machine comes in two sizes — 22x32-inches and 30x40-inches. The first machine, Autoprint Fine Coat 80 drip-off machine (22x32-inches) was launched in 2018 and Autoprint Fine Coat 105 drip-off machine (30x40-inches) was launched at Pamex 2023.

According to CN Ashok, managing director, Autoprint Machinery Manufacturers, the Autoprint Fine Coat drip-off machines are manufactured with two tower coating systems so that drip-off coating is possible in a single pass. This UV coater is attached with automatic driers which enables drying of both UV and aqueous/ water-based coatings.

Autoprint, since its inception more than three decades ago, has been adding new dimensions to the printing industry with a growing range of printing and post-printing machines. A dedicated R&D team that translates customer needs into thoughtful features, strategic alliances, win-win partnerships and a passion to excel, has seen Autoprint design, develop and deliver printing and post-press machines that meet international standards. Today, Autoprint has installed more than 13,000 machines in both domestic and international markets.

The machine
This machine can do various coatings like drip-off coating, full UV coating (gloss and matte finish), aqueous coating (gloss and matte finish), spot coating, texture coating, blister coating, etc.

“A single machine can be utilised for many coating solutions,” Ashok says, ‘The two-tower coating unit ensures drip-off coating in a single pass, and for other coatings, we can do it from the second tower itself. The coating towers can be used individually or simultaneously according to the type of coating.”

He says the targeted segment for the machine is all small-, medium- and large-size packaging units and commercial printers.

The market
Ashok says the machine is cost-effective, compared to inline coating systems, converted machine coating systems or any other coating systems in large format coating. Since it is an offline dedicated UV coating and drip-off machine, the simplified design enables it to produce more copies and it ensures per-day productivity. Printing presses can offer an affordable coating solution to the end users.

The machine price starts from Rs 75 to 90-lakh.

So far, Autoprint has sold a total of 25 machines. Among them, 20 are running successfully in India and five in the international market.

Ashok says customers looking for such a product in India usually look for the quality of coating, user-friendliness with safety features on the machine, after-sales service support, features to do more types of coatings in one machine, reliability of the machine, the brand and quick ROI.

According to Ashok, Autoprint customers are using the machine to do special drip-off coating for cartons of leading brands in the FMCG, pharma, and cosmetic industries, and industrial product cartons. “Some customers are also using our machines to coat for commercial jobs like posters, brochures, book covers, and invitations,” he adds.

The USP
According to Ashok, the USP of the product is that one single machine can be utilised for various types of surface protection coating applications. There is a provision to change anilox rollers according to the ink deposit thickness required for the job.

Cylinder grippers are easily removable and re-fixed. This helps clean the varnish spill-over on grippers, which ensures long-term, trouble-free running and enhances the life of grippers.

Spot coating is possible due to the cylinder design. The custom-made feeder ensures trouble-free feeding from 60- to 450-gsm substrates. An ink intensity adjustable power control system is provided on the machine to maintain the temperature in the drier to dry coating according to the ink application.

“The unique characteristic of the machine is that it requires less floor space, less power,” Ashok says. “A single machine for various types of coatings, it can be operated with minimum training. The dedicated off-line two-tower coating system assures various types of coatings with minimal makeready time.”
Ashok says that dedicated offline two-tower drip-off surface protection coaters are rare in the market. “Autoprint evidently is a solo player,” he says. “The other possibilities are old or used two-colour machines which have been converted for coating applications or inline conversion on secondhand multi-colour machines, brand-new multi-colour machines with the configuration of coaters, roller-coaters and screen printing methods.”

The productivity
According to Ashok, the machine can coat 5,000-6,000 impressions per hour.

“Previously, we were manufacturing coating machines for full surface protection coating, such as UV and aqueous coating. Now, this drip-off coating machine can do various types of coatings apart from the drip-off coating on 30x40-inches paper size too,” he explains.

He adds that with minimal training, any offset operator can operate this machine. Autoprint offers training to its customers onsite as well as in its factory. The machine comes with a one-year warranty period. After the warranty period, the company offers a preventive maintenance contract (PMC).

“Based on our study, most of our customers are using the machine at the optimum level and they are coating pharmaceutical cartons and FMCG products at the ratio of 60 and 40%. This machine has been designed and built with special features and it helps our customers fulfil their surface protection coating requirements as per the standards of the pharmaceutical and FMCG industry,” Ashok explains.

He adds that today, most large-scale packaging unit owners have understood the importance of automatisation, especially for the post-press process of packaging material. “Today, press owners are facing challenges like shortage of skilled manpower, more demand with less lead time, honouring on-time delivery commitment to their customers, quality of finished products with affordable price and stiff competition. These factors set the trend to change the units from conventional processes to automatic.

Ashok concludes that Autoprint’s target is to sell at least 15 Fine Coat machines for the financial year 2023-24. n

StarFlex from NBG Printographic Machinery

Rahul Kumar — Wed, 02 Aug 2023 14:03:00

The StarFlex by NBG Printographic Machinery, an inline rotary flexo printing machine with servo-drive controls, is a sophisticated piece of equipment that combines advanced technology and a robust structure to achieve high-quality printing results.

Nitin Garg, director, NBG Printographic Machinery, says that by employing the latest technology and controls, the machine enables high-speed, precise, and consistent printing of various products.

“It offers flexibility in terms of substrate compatibility, allowing for the production of labels, flexible packaging, thermal stationery, tags, IML, and more. The combination of advanced technology, accurate ink application, and substrate handling capabilities ensures superior print quality, vibrant colours, and excellent registration, meeting the print needs of different industries,” Garg says.

He adds, “With over 35 years of industry experience, NBG Printographic Machinery takes great pride in offering StarFlex, a meticulously engineered flexo printing machine. This kit is a testament to our commitment to excellence.”
Wide range of uses

StarFlex, which was launched in 2022, is designed for converters who specialise in producing labels, flexible packaging, in-mould labels, tags, and other related products.

The StarFlex is ideal for industries such as pharmaceuticals, food and beverage, FMCG, wine and spirits, and more. It produces labels with precise registration and vibrant colours. It's perfect for printing on flexible substrates, IML production, and different tag materials, as well as thermal paper for receipts and labels.

Most suitable for India
Garg says the pricing strategy and localisation of the machine to suit the Indian market make it highly suitable for an extremely price-sensitive market like India. "The machine is priced to align with the cost-conscious nature of the Indian market." He adds, "Offering a competitive price point makes it more accessible and attractive to printers operating within budget constraints."

The machine's advanced servo-drive controls and modular construction contribute to its cost-efficiency. "These features optimise production processes, reduce waste, and enhance productivity, ultimately providing a favourable return on investment for printers," he adds.

Garg explains that the machine is made in India, further strengthening its suitability for the market. "Localisation brings several benefits, including reduced import costs, shorter lead times, and improved after-sales support. It also promotes the growth of the local manufacturing sector and contributes to the country's economic development," he says.

The machine's ability to handle a wide range of substrates and integrate with various printing systems enhances its versatility. This adaptability allows Indian printers to cater to diverse customer demands, expand their offerings, and explore new markets without the need for multiple specialised machines.

The availability of local service and support networks is crucial in price-sensitive markets. With the machine's localisation, it becomes easier to access technical assistance, spare parts, and maintenance services, ensuring minimal downtime and uninterrupted production.

"The machine's sturdy structure and robust construction contribute to its reliability and durability. This minimises downtime due to machine failures or breakdowns, ensuring uninterrupted production and timely delivery of orders. Reduced maintenance requirements and longevity of the machine's components enhance the cost-effectiveness for customers," he explains.

The USPs
Garg says the machine offers versatility in terms of substrate compatibility, accommodating a range of materials from films to boards. It also has the capability to integrate with other printing systems like offset, gravure, rotary screen, and digital, allowing for customisation and flexibility in meeting diverse printing needs.

“The machine offers the unique advantage of integrating multiple printing systems. It can incorporate other printing technologies like offset, gravure, rotary screen, and digital. By combining different printing systems into a single machine, customers gain the flexibility to adapt to different printing requirements and explore new market opportunities,” he says. For example, a customer can combine flexo printing for labels with offset printing for packaging cartons, all within a single machine.

Another unique characteristic of the machine is its modular construction for flexibility. It allows for easy assembly, disassembly, and maintenance. This modularity enhances flexibility in adapting the machine to specific production needs or making modifications as required. For instance, a customer may need to expand the printing width or incorporate additional units for specific applications. The modular design enables such modifications, ensuring the machine remains versatile and adaptable to evolving printing demands.

The tool-less ink tray loading allows operators to load and unload ink trays without the need for tools or complicated adjustments.

Also, by customising the machine’s match tooling with their existing machines, the company provides a cost-effective solution that reduces tool library expenses. “Customers can utilise their existing tooling, eliminating the need to invest in new tools. This results in significant cost savings,” Garg says.

The productivity
Garg says the machine has been designed to perform at high speeds with faster setting time and lower wastage. “We have tested the machine at full production speed at 150 m/min for MLS and 200 m/min for ELS.

“The machine has been developed with easy-to-operate features where many of our customers are able to train new operators in less than two weeks,” he says, adding, “We provide in-depth training on the operation of the StarFlex machine, including its control panel, HMI interface, and servo-drive system,” he says.

The market
NBG has installed five StarFlex machines since its launch, three in India and two overseas. Garg says the company has a good number of orders in the pipeline, and the numbers will increase in the coming years.

“StarFlex represents the culmination of our extensive expertise and technological advancements. With its advanced servo-drive controls, modular construction, and exceptional versatility, this machine sets new benchmarks in the industry. It is engineered to deliver exceptional performance, reliability, and precision for a wide range of applications. StarFlex is a perfect alternative to European and American machines,” Garg concludes.

Uflex gearing up to capture the Chinese market with Asepto

Rahul Kumar — Wed, 20 Jun 2018 14:20:00

Talking about the potential that the brand holds, Ashwani Kumar Sharma, president and CEO of New Business Initiatives, Uflex, said, “This show, considered to be the carnival of processing and packaging technology industry will help us showcase ASEPTO’s holographic excellence in the untapped Chinese packaging market. We want to make a dent in the market by reaping the first-mover advantage.”

He added that Asepto is uniquely positioned and has all the capabilities for strengthening the market share of beverage manufacturers around the world, especially large markets like China. “Holography has not yet been explored by the Chinese. Our dynamic range of holographic packs, which is our USP, has the ability to grab a substantial market share in this segment,” Sharma added.

The Chinese premium aseptic carton segment is growing at an accelerated pace, which several food companies intend to penetrate into by exporting their products in metalised packs. “Here, Asepto has a clear strategic advantage to establish itself as the front-runner,” Sharma said, adding, “The brand with its unique UHT metalised/ holography packs happens to be the perfect and preferred choice in the significant six layer aseptic packaging market of China. As a matter of fact, Chinese consumers are increasingly looking for a premium appearance for their brands. This is where Asepto fits in.”

Metalised packages are not being sold by any aseptic packaging supplier locally in China, and only a couple of Chinese companies, apart from an international brand, are supplying metalised packaging material.

In China, portion packs and family packs with volumetric range from 200ml to 1,000ml are quite popular. However, that is not holographic packaging.

In the context of the market size, some Oceanian companies export almost 200 million metalised packs per annum to China. This outlines the market potential that India could capitalise upon. Hence, the introduction of an Indian brand providing holographic metalised packs will offer a greater degree of value-addition and protection to customers as compared to players who are presently not offering such premium packs. Consumers would cherish the high perceived value of the premium packs. The value proposition for retailers will be no less enticing either. Holographic packs will provide outstanding shelf performance to attract quality-focused consumers — leading to higher sales volumes thereby driving profitability.

Furthermore, holography as a feature only available through Asepto packs — is not restricted to just one kind of design; it opens up a plethora of options for retail beverage companies to choose artworks of their choice that best describe their product’s proposition to customers and further enhance the look and feel at the Point-of-Sale (POS).

Therefore, Asepto offers a compelling USP for beverage manufacturers dealing in dairy, juices and distilled beverages allowing them to evolve all new product lines/ brands by bringing about startling and strategic changes in their packaging.

Being fully integrated flexible packaging solution company that Uflex is, Asepto is complemented by the Aseptic Filling Line called Asepto Smart 78, the first-ever fully Indian aseptic filling machine with a capacity of Forming-Filling and Sealing 7,800 packages per hour for sizes ranging from 100, 125, 160 and 200 ml slim packs.

The machine comes equipped with special tools for superior and optimised operations. It has several significant features such as advanced integration with PLC, lesser electronic parts, better human interfacing making it operator friendly in addition to delivering highest production speed than any other comparable machines. The machine is low on maintenance which is a big advantage for the company’s clients as it will bring down the total cost of ownership. In this category, most of the machines generally process 7,500 packs per hour unlike the machine by Uflex that has a capacity of processing 7,800 packs per hour.

Uflex launches solventless white adhesive

Rahul Kumar — Mon, 14 May 2018 11:19:00

This solventless white adhesive works well on existing solventless lamination machines and will reduce the requirement of white ink coating on printed substrates, thereby giving substantial savings to converters. This product offers excellent opacity and wettability on metallised substrates. Other key features include good adhesion; suitability for low temperature applications (35 to 45 degrees C); and the ability to provide fast decay of primary aromatic amine.

Rajesh Bhasin, joint president, Uflex Chemicals, said, “This innovative and valued development substantially enhances our solventless adhesive portfolio. Given the myriad benefits that this adhesive brings for the convertors, we will market it globally. The demand is encouraging already.”

Made in India: Pressone Chemicals UV CTP plate developer

Rahul Kumar — Wed, 06 Dec 2017 11:13:49

UV CTP Plate Developer is one of the essential chemicals for image development on printing plates, especially in UV CTP/CTCP. In this, Ludhiana-based Pressone Chemicals is an up and coming supplier, manufacturing more than 18,000 litres of UV CTP Plate Developer per month to serve more than 100 customers.

Established in 2012, the chemical manufacturing business launched its UV CTP Plate Developer in July 2015. “Right now, we manufacture more than 18,000 litres of chemicals per month,” says Mukesh Chauhan of Pressone Chemicals. Now, the company is planning to increase production as it we found the chemicals to be one of the fastest growing segments.

Chauhan has around two decades of experience in the chemical business, primarily as an employee of a Delhi-based pre-press equipment manufacturing company, before setting up his own company.

Pressone Chemicals manufacturers a range of pre-press and press room chemicals.

The pre-press segment range includes a PS Developer, PS Thermal Developer and Plate Processor Gum.

The press range includes fountain solutions, washes, alcohols, plate cleaners and corrections fluids, tack reducers, printing ink dyers, printing press care products and anti-set off spray powders.

According to Chauhan, any pre-press bureau and offset printer with UV CTP/CTCP can use its UV CTP Plate Developer. “Today, we serve 100 customers. Of these, 75 are pre-press service bureaus and 25 are offset printers,” he says.

The market

Pressone Chemicals has a strong distribution network in all the major cities of Punjab, including Baddi, Mohali, Chandigarh, Ponta Saheb, besides in Bareilly, Lucknow, Allahabad, Varanasi, Patna, Ahmedabad and Delhi-NCR.

“Our existing distribution set up is serving customers in the North and Delhi-NCR. We are working to increase the network and serve more cities in other parts of the country. Being a north-based manufacturer, we have our own advantages,” says Chauhan.

Chauhan is optimistic about growth and he has reasons for it. The segment has grown fast in the last five years and will grow well in future. One reason being the cost of UV CTP/CTCP printing plate is more economical compared to other technologies available in the market. Most UV CTP/CTCP developers provide 2,400dpi printing plates and to some extent in quality, it competes with thermal plates.

According to Chauhan, films have now become obsolete. Image development directly on printing plates is the norm now. This is another reason why there will be a rise in the demand. However, according to Chauhan, the most import factor is that the plates are economical.

Chauhan says as per his estimation, around 1,500 CTCPs are running in India and per CTCP device consumes an average of 150 litres of chemical. Thus, it is a 200,000 litre per month market. “We are catering to less than 20% of the market. So opportunities are huge,” he says.

The chemical

UV CTP Plate Developer comes in liquid concentrate form in a 25-litre pack. It develops images on printing plates. “We recommend using the developer with RO water and ratio between developer and water must be around 1:8/7. Some use it with normal water as well but for better result RO water is necessary,” Chauhan says.

As it is an alkaline product, users are advised to wear hand gloves while using the chemical; without hand gloves it can be harmful.

“And especially, cover your eyes while using the chemical because naked eyes are easy targets for any chemical mishap. Ideally, don’t let it touch your skin,” he cautions.

Benefits

The benefits of Pressone’s UV CTP Plate Developer? Chauhan says, “Our developer helps cleaning of plate processor. Otherwise, it can block the entire process. It does not create a layer on the tank of developer and brush of processor. Brush is an expensive part of the processor. Our UV CTP Plate developer is universal. It means it is suitable for each and every plate available in the market. Our developer ensures that the first plate is printable and saleable, thus clients can save their money on printing plates cost.”

Ahmedabad-based N-VIR Process; Noida-based Anupama Printing Solutions; New Delhi-based Japan Art Press and SS Graphics; Chandigarh-based Gagandeep Photo Lith; Mohali-based Ishan Print Services; Jalandhar-based Lucky Processors; Ludhaina-based Unique Process; Bareilly-based Anoopam Press; Lucknow-based Fine Graphics; Kanpur-based Perfect Chem & Technology and Jaipur-based Raj Block are a few key customers of Pressone Chemicals.

Around 25 people work in the 11,000-sq/ft chemical production facility in Ludhiana.

Customer testimonial

"We are using the UV CTP Plate Developer manufactured by Ludhiana-based Pressone Chemicals for the last two years and we found it to be very friendly in our operation. Our consumption is around 400 litres per month. The best part of the developer is that there is minimum sludge, or shall we say no sludge. Plus the does not go down. We use the developer on multiple printing plates and found it to be smooth. It truly is a universal developer. Pressone Chemicals’ Developer helps in functioning and keeps the process clean. People must use it. Working in a price-sensitive industry and market, the chemical manufacturing company provides the Developer on economic rate."

Arun Gupta, Japan Art Press, New Delhi