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Recykal's platform manages the complete lifecycle of a DRS product

Rahul Kumar — Mon, 06 Apr 2026 10:51:00

Rahul Kumar (RK): What role does Recykal play in enabling the digital infrastructure for the Goa Deposit Refund Scheme (DRS), particularly in terms of QR code generation, serialisation, and traceability?

Vikram Prabakar (VP): As the appointed scheme operator for Goa's DRS, Recykal manages the scheme's digital infrastructure, including generating and managing unique serialised QR codes for participating brands. Each QR code carries embedded product information SKU details and deposit value, enabling end-to-end traceability and verification of every packaging. Under the ambit of the scheme, Recykal is responsible for QR generation, serialisation, and allocation, ensuring full traceability across the DRS ecosystem.

RK: How does the technology platform manage the lifecycle of the packaging from QR code creation and packaging integration to consumer scanning and recycling verification?

VP: Recykal's platform manages the complete lifecycle of a DRS product, whether beverages or other products through a secure, QR-based system spanning stages:

QR Generation: Once a SKU is registered, brands can instantly generate unique serialised QR codes (USIs) as per their requirement through the brand portal, accessible via email-based login. Each QR embeds key product metadata like manufacturer, bottling facility, SKU data etc. A deposit value is attached to every QR code at the time of its generation, ensuring each container in the market carries a defined deposit liability from the outset.

Packaging integration: The QR is printed on labels or stickers at the packaging converter or online at bottling facilities using variable data printers (digital, TTO, or laser) which are integrated with the DRS software.

Consumer return and verification: When a consumer returns the container at an RVM or manual collection centre, the QR is scanned and validated against the central system for authenticity, deposit eligibility, and redemption status. If valid, the deposit refund is instantly processed via UPI or cash, and the USI is marked as redeemed to prevent duplicate claims.

Real-time data flow: Every scan and redemption event syncs back to the DRS platform, enabling real-time reconciliation of deposits, refunds, and material recovery.

RK: What kind of data management and backend architecture is required to handle millions of unique QR codes while ensuring accuracy, security, and real-time tracking?

VP: Recykal's backend architecture is built for massive scale, security, and real-time traceability, resting on three core pillars:

Scalable cloud infrastructure: The QR generation engine is hosted on AWS and capable of generating up to 1 crore QR codes per minute with 1,000 concurrent users. It supports thousands of simultaneous printers and features auto-scaling to dynamically adjust resources during peak loads, ensuring uninterrupted performance.

Security and uniqueness safeguards: Every USI (unique scheme identifier) is protected by cryptographic encryption, preventing reverse-engineering or forgery; collision-free logic, hashing and collision-detection ensuring no two QR codes are ever duplicated and tamper and counterfeit detection, where each QR code is uniquely tracked. Once the associated deposit is redeemed, the QR status changes to “retired,” enabling the system to detect tampered or duplicated codes during subsequent scans.

Audit trail and irrefutability: Every USI event is permanently logged with a timestamp, originating facility, and user details, creating a full, irrefutable audit trail. Once generated, a USI's origin and validity cannot be disputed, making it legally defensible in compliance checks.

Together, these controls ensure accurate deposit tracking, fraud prevention, and counterfeit protection across the entire DRS ecosystem.

RK: How does the Recykal platform integrate with stakeholders across the ecosystem, including beverage brands, printers/converters, retailers, reverse vending machines, and recyclers?

VP: Recykal's platform integrates with every stakeholder in the DRS ecosystem through a unified, cloud-based infrastructure:

Brands: Brands generate unique serialised QR codes on demand through the brand portal (accessible via email-based login), using Recykal's secure, cloud-hosted cryptographic engine. These QR codes are then securely transmitted to integrated printers at label converters or bottling facilities, ensuring each code is unique and printed only once. The platform offers open access to any printer at the brand or facility that can connect with the scheme operator to integrate.

Printers and packaging converters: Printer OEMs at the label converters and brands integrate their variable-data printers (digital, TTO, TIJ or laser) with the DRS software. The system streams serialised QR codes in real time for both pre-printing and online printing, logging every printed code to maintain batch-level traceability.

Retailers and return infrastructure: Retailers and return points connect via collection applications or RVMs. On container return, the QR is scanned and validated against the central database for authenticity, activation status, and deposit eligibility — triggering the refund instantly upon successful verification.

RK: What are the biggest challenges in implementing a digital deposit refund system in India, and how can technology help ensure transparency, fraud prevention, and efficient recycling outcomes?

VP: Implementing a digital Deposit Refund System in India presents several challenges — but technology-led infrastructure can effectively address each one:

Supply chain scale and complexity: India's beverage market spans thousands of brands and bottling facilities with diverse packaging formats. Integrating QR marking into high-speed production lines without disrupting manufacturing requires a centralised platform supporting high-volume QR generation, serialisation, and direct printer integration.

Stakeholder coordination: A DRS involves brands, converters, retailers, collection centres, and recyclers. A unified digital platform with real-time dashboards and data visibility ensures smooth coordination and operational transparency across all stakeholders.

Fraud prevention: Risks include duplicate QR codes, unauthorised claims, and multiple redemptions. These are mitigated through cryptographic serialization, encryption, geofenced applications, and real-time validation — ensuring each QR is redeemable only once, backed by a full audit trail.

Deposit reconciliation: Managing deposit flows across millions of containers is complex. Digital platforms link each QR to its deposit value and track its lifecycle, enabling accurate reconciliation and preventing financial leakage.

Collection infrastructure and consumer convenience: High return rates depend on accessible return channels. Integration with RVMs, mobile collection apps, and digital payment systems (UPI/cash) enables instant container validation and quick refund processing.

Recycling verification and traceability: Ensuring collected containers are actually recycled requires end-to-end tracking. The platform traces containers from production through redemption to recyclers, generating reliable material recovery data for regulators.

RK: Do you see digital DRS platforms becoming a national model for waste management and circular economy initiatives in India, and how is Recykal preparing for large-scale adoption?

VP: Yes, digital DRS platforms have strong potential to become a national model for waste management and circular economy initiatives in India. With growing regulatory focus on traceability under frameworks like the Plastic Waste Management Rules 2016 and the expansion of deposit-based recovery systems like the Goa DRS, a digital QR-based infrastructure offers the transparency and scalability needed to manage post-consumer packaging at a national scale.

A digital DRS creates end-to-end traceability — from QR serialisation at production to consumer returns and recycling verification — ensuring every container placed in the market is accounted for. This enables accurate recovery rate tracking, prevents deposit leakage, and generates reliable data for regulators and producers alike. As India advances toward a circular economy, such systems can serve as the backbone for monitoring material flows across multiple product categories and states.

As for large-scale adoption, Recykal is implementing India’s first digital Deposit Refund Scheme and has already built a comprehensive ecosystem to support brands in seamlessly integrating into the DRS framework, ranging from QR-based lifecycle management and packaging integration to collection infrastructure and recycling verification. This positions Recykal as a benchmark for future DRS rollouts across states and product categories in India.

Allstein presents new Allstein Genesis at Drupa

Rahul Kumar — Mon, 01 Jul 2024 09:30:00

The company said as the printing industry is currently facing a shortage of skilled workers all over the world, this machine reaffirms Allstein’s commitment to establishing fully automatic production in the flexo printing industry.

Rather than press operators getting their hands dirty while cleaning aniloxes, changing inks, changing blades or lifting heavy-weight print hardware, Allstein delivers a future where printers can focus on what they do best, signing off good quality print.

The automatic workflow allows predictable and consistent changeovers, making production planning easy. The Genesis decides when the aniloxes need cleaning, when blades are worn or seals require replacement. It cleans critical components and puts everything back together 24 hours a day, without being asked.

More than 600 interested customers attended the exclusive Allstein Genesis demo during the 10-day show.

The first installations are scheduled at customer sites in 2025.

Panel discussion on global opportunities in packaging held

PrintWeek Team — Mon, 27 May 2024 11:13:00

Moderated by Dr Ainian Shahidi, managing director of 4 Sixes Packaging Marketing, the panellists included Dr Rajesh Agrawal, general manager, R&D, Modi Mudipharma; Naveen Stuart, cluster packaging manager, Health, SoA, Reckitt India; Sithanshu Shekhar Bag, AVP, head packaging operation and projects, Emami Agrotech; and Dr AK Datta, packaging consultant, Indian Institute of Packaging.

In his presentation, Agrawal talked about the huge market for packaging. The Asia Pacific region is the fastest-growing one, and India is in the third position and is growing at double digits. He said global opportunities are immense for Indian professionals and entrepreneurs, and they need to focus more on innovation, sustainability, regulations, R&D and audits. He also highlighted the importance of knowledge, education, and training.

Stuart spoke about various challenges to be handled by the Indian packaging industry to encash global opportunities. These include infrastructure development, including power, logistics, and warehousing; waste legislation and environment policy; technology gap; and regulatory challenges.

Bag emphasised the importance of supply chain and logistics costs. He said that two-thirds of India falls under two seismic zones. The warehousing facilities can be modernised by going vertical. That will also bring down the overall warehousing cost. Packaging design is a major tool which can be adapted to be competitive in the global market. Digitalisation and automation must be adapted at a fast pace to achieve accuracy, waste reduction and cost improvement per unit.

Datta was vocal about the importance of audit. He said all the processes and specifications must be documented. Audit is generally seen as a fault-finding activity but actually, this adds value to the organisation and helps the organisation grow better and bigger. Standardisation of processes, optimisation of specifications and following the overall audit of the Indian packaging industry can help encash and enjoy global opportunities in packaging.

Shahidi exuded an impressive level of dynamism and passion as he undertook the role of session moderator. Throughout the session, his infectious energy reverberated, captivating both the panellists and the attentive audience alike. With finesse and adeptness, Dr. Shahidi orchestrated discussions, seamlessly weaving together insights and perspectives while fostering an environment conducive to meaningful dialogue. His dedication to engaging participants ensured that every moment of the session was not only informative but also stimulating, leaving a lasting impact on all those in attendance.

Labelexpo 2023: Dow highlights the power of innovation

Charmiane Alexander — Tue, 12 Sep 2023 01:28:00

As part of Dow’s commitment to delivering a sustainable future for the world through materials science, Dow launched SYL-OFF Protect – a carbon-neutral selection of SYL-OFF Silicone Release Coatings. Certified by an independent third party according to PAS 2060, these products offer the same quality and performance customers in the label industry expect from standard SYL-OFF Silicone Release Coatings, with the added benefit of a reduced carbon footprint.

“Many of our customers in the label industry are looking for innovative technologies that not only provide them with the quality they need but also help them meet their sustainability targets. Our selected range of SYL-OFF Protect Silicone Release Coatings are making it possible by combining reduction of carbon footprint without compromising on quality,” said Nathalie Gerard, European market manager for Dow Pressure Sensitive Industries.

Attendees will also have the opportunity to learn more about Dow’s portfolio of high-performance water-borne label acrylic adhesives that perform under pressure and demonstrate exceptional adhesive strength, UV resistance, temperature stability, and processing efficiency.

INVISU 7007 wash-off label adhesive, which is Dow’s second product launch at Labelexpo Europe, enables the separation of polyolefin-based (PE, PP) filmic labels from PET bottles for enhanced PET recycling. Additional performance benefits of this acrylic technology include moisture resistance, easy converting and processing and has been acknowledged by the Association of Plastic Recyclers (APR) for its alignment with caustic wash recycling guidelines.

“The launch of INVISU 7007 water-borne adhesive is an exciting development directly aligned with the label industry’s push towards a circular economy. It addresses both converters’ demand for reliable and high-performing label solutions as well as recyclers’ needs for cleaner recycled materials. Innovations like this are a testament to the possibilities that can be enabled by material science,” said Izzat Midani, marketing manager adhesives at Dow Packaging & Specialty Plastics.

Labelexpo 2023: HB Fuller showcases its labelling adhesives

Aditya Ghosalkar — Tue, 12 Sep 2023 01:26:00

The Swifttak PS 8405 is a water-based pressure-sensitive adhesive (PSA) with non-water whitening properties. Designed for those seeking a premium PET label with a no-label look, this water-based PSA offers remarkable benefits, like boasting high resistance to water whitening to help labels maintain their appearance, even in challenging environments and temperatures.

This adhesive delivers superior performance with excellent clarity and optimised peel, tack, and durability properties. It is also ideal for applications where aesthetics matter, as Swifttak PS 8405 offers a blend of functionality and no look transparency.

Ultra-removable and highly repositionable Gel-Tac products are based on water-based acrylic, pressure-sensitive microsphere technology. With HB Fuller Gel-Tac microsphere adhesives ready-to-go formulation, photo albums, consumer advertising, masking tapes, wall or window decals, graphics, wallpapers, liner-less labels, and tape constructions can be easily repositioned or replaced.

The Earthic portfolio is the company’s recently launched sustainable product brand for many packaging applications. Swiftmelt Earthic 9010E is a circular hotmelt PSA for labels that is a near zero CO₂ pressure-sensitive adhesive that helps lower overall CO2 operations impact while responding to the demanding packaging requirements. The product offers excellent performance on a wide range of substrates and excellent adhesion at low temperatures, and it is based on 80% fossil-free adhesive.

These products and innovations allow customers to deliver design innovation and product performance, differentiate brands and accelerate manufacturing. HB Fuller customisation capabilities make it possible to address both business needs and industry requirements toward a more circular economy.

Labelexpo 2023: Esko, X-Rite Pantone spotlight one connected workflow

Abhay Avadhani — Tue, 12 Sep 2023 01:24:00

“Visitors to our combined booth will discover how Esko and X-Rite Pantone are helping the packaging industry achieve consistent performance from concept to market,” Jan De Roeck, Esko director of marketing, industry relations and strategy said.

He added, “Using demonstrations of the latest technology, displays and expert discussions, we will highlight how an end-to-end ecosystem of new colour management software and measurement solutions supports digital workflows to increase efficiency, enhance sustainability, and drive growth opportunities.”

At their booth, Esko and X-Rite Pantone are showcasing their entire range of digital workflow solutions from design through production. Highlights include:

• Phoenix, Esko’s AI-based tool that unlocks planning and imposition productivity improvements, with a seamless interface between prepress data and production data in Esko applications.

• The award-winning CDI Crystal XPS 4835, utilising UV main and back exposure to produce highly consistent digital flexo plates while minimising waste.

• AVT Helios System, which automatically inspects printed labels or packages for defects and imperfections, delivering exceptional quality results and eliminating customer rejections.

• The latest Esko Software version, which delivers a combination of prepress editing and cloud-based workflow automation solutions, is now more integrated and connected throughout the entire pre-press workflow.

• X-Rite eXact 2, the most connected and easy-to-use handheld spectrophotometer that can measure colour across various substrates - including flexible film and paper - in a single device, while also verifying customer standards.

• X-Rite ColorCert Suite, which works with Esko WebCenter, AVT’s Spectralab, and eXact 2 to provide printers an overall view of print quality and color performance in a single number score to confirm compliance with brand specifications.

• PantoneLIVE digital color libraries for the creation and sharing of accurate brand colour standards that are achievable across printing technology and substrates.

“Error and waste reduction have a direct impact on the environmental footprint of a packaging businesses,” said Jan. “As we are all looking to protect the environment in which we live and to safeguard it for future generations, we must reduce the impact of our operations on the environment. With sustainability and digitalisation fundamentally altering how the industry operates, it is imperative that today’s label and packaging companies invest in digital workflow technology that enables them to boost efficiency, reduce costs and improve their overall productivity,” he said.

Jon-Michael McCartney, director, print and packaging, X-Rite Pantone, added: “The combined X-Rite Pantone and Esko ecosystem helps to streamline the design, prepress, formulation and production workflow with the sharing of packaging and colour data to reduce errors and improve reporting.”

He added, “With a digital workflow you can eliminate on-site press approvals, clearly define and share print requirements across a global supply chain, reduce waste and rework, save resources and support sustainability goals.”

Labelexpo 2023: Emsur, Karlville, SK Microworks, Siegwerk join forces for #SleeveConnect project

Disha Chakraborty — Tue, 12 Sep 2023 01:21:00

Together, they have given rise to an ingenious packaging solution that not only facilitates striking bottle designs but also champions environmental sustainability.

The #SleeveConnect project was launched at Labelexpo Europe 2023, held on 11-14 September.

The washable inks of the rPET bottle’s c-pet sleeve make it an easily recyclable mono-material that can also incorporate innovations in the recycling process, such as a digital watermark that allows for accurate detection during sorting.

The bottle produced by the innovative startup BTC Concept has a high-quality shelf impact thanks to the high opacity white sleeve which gives more visual body to the design and enables a non-coloured bottle to give both high-quality shelf impact whilst being 100% recycling friendly under the correct reprocessing conditions. The different finishes, such as Soft Touch or Matt Effect, make the product even more attractive and demonstrate the endless possibilities when printing the sleeve.

Uncoloured bottles will be a good source of high-quality recyclate for the future and this sleeve solution is the ideal complement for any type of transparent bottle. The production process is realised on the Karlville machines after the sleeve has been processed in Emsur with washable inks and coatings from Siegwerk and C-Pet shrink film from SK Microworks.

Labelexpo 2023: Durst launches Hawk Eye technology

Rahul Kumar — Tue, 12 Sep 2023 01:19:00

In addition, it significantly reduces set-up time and waste, resulting in enhanced efficiency and a more competitive total cost of ownership for the Tau RSC platform printers.

Durst Hawk Eye includes a scanner system, workstation and touchscreen monitor. It corrects print mistakes, such as missing nozzles, inline and in real-time. In the rare event of a printhead nozzle malfunctioning, in-built artificial intelligence systems automatically detect and localise any problems without any speed reduction. Neighbouring nozzles then compensate with larger drops to ensure that outstanding print quality is maintained. Operators do not need to complete any set-up and there is no need to print a special test pattern.

Other announcements by Durst at Labelexpo include important ink developments. It is expanding the Tau RSC ink portfolio with the new Tau RSC LED inks. The new ink set, available in CMYK, with optional orange, violet, green and white, is increasing the attractiveness of the Tau RSC press portfolio. By significantly reducing the energy consumption during the operation and by eliminating frequent UV bulb and reflector changes, the overall TCO of the Tau RSC presses to become even more attractive. The new Tau RSC LED ink combines the excellent print quality and performance of the existing Tau RSC UV ink with Durst Group’s roadmap towards a more sustainable printing industry. It provides reduced energy consumption and a reduction in consumable cost and maintenance time. This results in economic benefits for customers and a reduced ecological footprint. The vivid inks create a huge color space allowing to precisely reproduce important brand colours.

Durst has also unveiled the new Tau RSC UV Ink 3 high-speed UV inks, formulated without the need for TPO photoinitiator.

Durst’s software label ecosystem also features prominently on the Durst stand. Tau printers are equipped with Durst Workflow Label, pre-press and production software, and Durst Analytics, the analytics and monitoring tool, to make the printer a production unit from day one. All Durst software solutions are modular and can be easily managed through a web-based user interface. A browser-based VDP editor for creating and managing variable data is available in the workflow.

The show also provides the platform for Durst Group to show live running of the Tau 510 RSCi single pass press, which is equipped with new automation features. The press on its stand is equipped with the powerful double white feature, allowing excellent opacity white ink printing at 80-m/min.

“Our team of experts are on hand at Labelexpo to provide personalised demonstrations, answer questions and discuss how our solutions can revolutionize customers’ printing operations,” said Martin Leitner, product manager of Durst Group. “The Durst Hawk Eye is a game-changer for the digital printing industry. This technology will greatly increase productivity and efficiency, but, more importantly, it will reduce waste and the carbon footprint of our customers. We are thrilled to introduce this innovative solution to the market and provide exclusive information during Labelexpo.”

Labelexpo 2023: Durst, Omet strengthen strategic partnership

Rahul Kumar — Tue, 12 Sep 2023 01:18:00

“We are excited to offer now the full range of integrated conventional and digital printing solutions to all labels and packaging converters around the world,” Thomas Macina, sales director, labels and packaging at Durst, said.

The current XJET platform, which has been the leading hybrid solution in the market with multiple installations worldwide, will be further improved and expanded. The global sales and service structure of the Durst Group will fully integrate the solutions. A joint product roadmap will speed up development and create unique solutions tuned for the next generation of highly integrated printing presses.

“Omet is proud to strengthen the partnership with Durst. We are combining the best technologies to offer excellent solutions and added value to customers,” Marco Calcagni, sales director, Omet, added.

Toph Packaging forays into packaging with Bobst M5

Rahul Kumar — Mon, 03 Jul 2023 12:32:00

Priyank Virmani, co-founder, Toph Packaging, said, “We initiated the business during lockdown. We were at home and were planning to diversify. Someone suggested label converting. We downloaded the knowledge from various platforms and opted for it.”

Virmani comes from a business family with stakes in real estate and rice mills. So, label printing was a completely different business, but Virmani said he opted for it because of its creativity. “We evaluated multiple machines and found Bobst to be suitable for our requirements, especially as a new entrant. Our press is servo-driven, and we can do shrink sleeves and short runs on the machine,” he said.

The machine can run at 200-mpm.

Virmani, an engineer and management degree-holder, said, “We are catering to customers from pharma, and cosmetics and trying for new applications for the segments. Response from the market has been good. We are supplying to the 100-km radius around our plant and in Delhi-NCR too.

On the name, Toph, Virmani said that he believes in spirituality and Toph is a Japanese word which means grooming/expanding lotus. “We believe that everyone is the same and we started the plant with the same thought. This means empathy for your employees. A human factor must be there. We are happy with the machine and our diversification. Packaging is going to grow, and so are labels and so are the label converters,” he said.

The company’s team of 20 people works in a 600-sqm factory in a single shift.

“Having a single machine has its own limitations, but fortunately being a robust machine, we haven’t seen a breakdown. Digital printing for labels can be an option in future but only as per market demands. Our focus is on specialised jobs along with routine production. After our diversification from rice mills to real estate to printing, we realised that anything can be done with appropriate research,” he explained.

He added that being a new entrant, it was tough initially, but the company is now settling down. “An aggressive approach is required to expand the business. We are working to achieve Rs 50-crore turnover in the coming five years,” Virmani said. “The price war is not good for anyone because raw material costs can’t be controlled and cost-cutting is not good for anyone. Substandard material is killing people.”

DGM books five machines during IndiaCorr

Rahul Kumar — Mon, 17 Oct 2022 12:00:00

Vapi-based Subhashish Paper has ordered Technocut 1050S automatic die-cutter with stripping, its third machine from DGM. “Repeat orders always show the strength of your products and after-sales service,” Puneet Aggarwal, managing director, DGM Automation India, said.

Another customer from Jaipur has booked Technocut 1050 automatic Diecutter and TechnoFold 1100PC automatic folder-gluers. The machines will be installed in December 2022. Aggarwal said the customer booked the DGM kit due to its strong presence in Jaipur with its direct and realistic feedback from the users.

Another SmartFold 1100PC was booked by a customer from the western region, and a TechnoFold 1100PC by a customer from the northern region. The machines will be installed within this month from the company’s India stock.

Aggarwal said, “We are thankful to the industry for its positive responses and support for our products. We have installed more than 100+ converting machines in 4 years and numbers are increasing. The industry is looking for smart, fast and excellent value for money equipment and DGM India is happy to provide those.”

ProductWatch: Print Dynamic’s Sterilisation indicator ink

Abhay Avadhani — Mon, 03 Oct 2022 20:48:00

WhatPackaging? (WP): What does it do?
Print Dynamic (PD): These inks fall into the category of indicator inks. The ink confirms the successful and effective completion of an exposure process to a sterilant by a chromatic transition .

WP: Explain what it's suitable for?
PD: Sterilisation indicator inks are required to verify whether a material (labels, pouches or tapes) has been adequately exposed to a sterilisation process to ensure that all pathogens are neutralised. Sterilisation is a process that eliminates all forms of life and other biological agents and can be carried out through heat ,chemicals, irradiation, high pressure and filtration.

Articles that have direct application on humans and animals are subjected to sterilisation including drugs, surgical equipment, medical devices, nutraceuticals, food and packaging of food products. The methodology is to confirm by a visual indication that the sterilisation process has been successfully accomplished The inks are used to print labels which can be affixed onto any article which is sought to be sterilised.

WP: When was it launched and what market is it aimed at?
PD: We launched it recently after all successful trials. The market we aim for is the entire medical sector covering all hospitals, dental clinics, medical universities and institutes and the food packaging sector. Sterilisation indicator labels are mandatory in more than 100 countries worldwide and the market has the potential to keep increasing.

WP: Which kind of raw materials does it deploy?
PD: The materials are proprietary formulations and basically organic chemicals which are safe, non toxic and no harm to either the print process or the end user

WP: How was the technology adapted by print firms in India?
PD: We are working with just one potential company who will print and market labels nationwide and worldwide. Also who will market our ink exclusively to those who are already engaged in the business of printing and selling labels with inks sourced from other ink companies.

WP: How does it differ from similar products in the market?
PD: The quality of our ink conforms to the international standards and it will be available as an import substitute at an affordable price. There are only three companies in the world who make creditable inks in this sector – we are the fourth .

WP: What’s the USP?
PD: Our quality satisfies the required standards but at a comfortable price compared to the foreign brands. So it creates a wide market for printers in India to get into this business without having to import from other countries.

WP: How easy is it to use?
PD: The inks are backed by easy-to-comprehend technical data sheets for conventional flexo, gravure and screen inks. It is easy to use and easy to print for those who get accustomed to these inks.

WP: Assembly line speed?
PD: The assembly line speed varies in the print process from screen to flexo to gravure; with varying print parameters of speed.

WP: How does it score on the merits like being trouble-free?
PD: The inks perform well in their respective printing machine processes with due observance of dilution, speed and requisite controls. For example; the water based flexo steam sterilisation inks print smoothly provided the recommended anilox is used, press room ambient temperature and humidity level is maintained. Also inks should not be wrongly diluted or mixed with any unrecommended materials.

WP: What about recyclability and sustainability of the sheets?
PD: The substrates used range from papers to plastics which are candidates for recyclability along with our inks which are formulated with biodegradable materials in the water based segment.

WP: What are the application areas?
PD: The inks are used for products that require sterilisation to ensure that all products which can be exposed to any kinds of pathogens are effectively disinfected and made safe for human or animal contact.

For example surgical instruments which are in contact with human skin and internal tissues when surgeries are being done – they have to be completely disinfected before they are used to operate.

WP: What kind of manufacturing compliance does the ink follow?
PD: The inks are dispersed and milled in dedicated machinery and equipment to ensure that they would pass all standards for presence of contaminants. The inks are tested for viscosity and solids are ensured from batch to batch because any variation in solids will alter the print colour and the transition colour density.

WP: How sustainable are these inks?
PD: The water-based inks are good candidates for sustainability goals.

WP: What’s the price? How affordable are these inks as compared to competition?
PD: The price is below the competition which has ruled the roost mainly due to a veritable monopoly.

WP: Key customers?
PD: The key customers are from an unknown segment of the printer community being a very niche field

WP: Contact person (details)?
PD: Akil Contractor
Print Dynamic
Mumbai
9820038704

WP: Technical specifications of the product:
PD: Technical specifications of water based steam sterilisation indicator inks:

SPECIFIC GRAVITY

1.3 TO 1.39

TYPICAL VISCOSITY

1100 CPS

VOC

TYPICAL SOLIDS

60+-2

APPLICATION METHOD

FLEXOGRAPHIC

RECOMMENDED ANILOX

100 LINES PER inch

40 LINES PER cm

DRYING TEMPERATURE

43- 52 DEG C

110 -125 DEG F

PRESS SPEED

200-400 ft /min

60 -120 metres /min

SUBSTRATES

Films, foils, papers, tapes ,thermal paper stocks

THINNER /DILUENT

Distilled water

PACKING

1 kg, 5 kg , 20 kg plastic pails

WARRANTY PERIOD

6 months from shipment date

XSYS sharpens its focus in APAC

Rahul Kumar — Mon, 19 Sep 2022 11:31:00

The well-known products and brands that keep XSYS positioned firmly as number one or two in each segment where it is active include Nyloflex flexographic solvent and thermal plates and equipment, Nyloprint letterpress plates and equipment, Nylosolv washout solvent, Rotec sleeves and adapters, ThermoFlexX TFxX imagers, ThermoFlexX Catena plate processing equipment, and Woodpecker surface screening solutions.

“The reaction from our customers to the formation of XSYS as a more agile solo operation has been great,” said Roy Schoettle, VP XSYS Asia Pacific. “They understand that we are now in a position to react much faster, because we are more focused and more flexible. But they also know that they are dealing with the same great team which means the continuity is there.”

The APAC region is comprehensively covered by 28 pre-press experts and technical engineers, a large team which is set to expand further with six more staff joining over the coming months. “What is special about the XSYS team in APAC is that most of us have been with the company for decades; in fact, the average length of experience here is 19 years,” said Roy, who himself has been part of the story for 34 years – starting out at BASF and staying on as it became Flint Group and now XSYS. For the past 22 years, his focus has been on plates and plate processing, helping bring to market a whole host of XSYS innovations, such as Nyloflex Xpress Thermal System and ThermoFlexX Catena.

Supporting Roy Schoettle is a team of specialists, who are well-known throughout the region for their dedication and in-depth knowledge of the flexo print process.

Converters in the APAC region are experiencing many pressures and challenges that are forcing them to find new innovative technologies and working methods. In a region that has witnessed a lot of change, XSYS is working closely with its customers to ensure they optimise their business models by implementing best-in-class solutions across their pre-press operations.

Innovation is central to tackling these difficult market conditions. XSYS offers a wide range of market-leading solutions that can improve efficiencies, deliver consistent quality, and cut waste in answer to these challenges, such as the Nyloflex Xpress Thermal System, which helps increase sustainability and deliver exceptional plates in less time without the use of harmful solvents and at lower costs. Additionally, brand owners demand colour consistency across multiple applications and multiple production sites meaning plates must be of equal high quality, so a job can be reproduced easily no matter where it is being printed.

Proximity to customers is another of the main aspects of the XSYS business model. With local technical teams on standby, the company can guarantee that help is always on hand to minimise any unwanted downtime. The teams also educate and train operators in all aspects of machine operation on an on-going basis to help customers overcome the problems with staff shortages and low skill levels.

SIG eyes India as next destination for strategic investment

Rahul Kumar — Fri, 15 Apr 2022 18:43:00

SIG is on a strong growth track. In the annual results for 2021, the company showed core revenue of 2.05-billion euros with 6.6% year-for-year growth at constant currency. The company is also strategically investing in broadening its packaging portfolio with the planned acquisition of Scholle IPN, which increases SIG’s capabilities to include bag-in-box and spouted pouch solutions.

SIG entered the Indian market four years ago. Presently, India is one of the fastest growing markets in the SIG world.

SIG India’s journey started with two iconic customers, ITC and Coca Cola India, as it set up its local headquarters in Gurgaon in November 2017. Its exponential growth journey in the country has seen the aseptic packaging major gain entry into most leading dairy and juice brands in India, including Coca-Cola, Amul, Dabur, Varun Beverages (PepsiCo bottler), ITC, Haldirams, Milky Mist, and Godrej Creamline. Today, with a base of 17 high-speed filling machines across the country and a full-fledged, experienced local team, SIG is looking to further accelerate its growth trajectory in India.

Sigrist said, “After opening our second plant in China and starting construction of a plant in Mexico for the North American market, India is our first priority for the next investment in a new packaging plant. The decision-making process is still ongoing, but we are very confident that we will be able to start building a plant in India in the near future. The construction time for a new SIG packaging plant is 12 to 18 months.”

SIG’s USP has been its unique technology that allows the company to offer unmatched volume flexibility along with high speed, across its machine platforms. This lets brands change volume sizes and maintain key price points — crucial in a dynamic market like India. SIG’s packaging technology can also be used to fill beverages with fruit chunks, cereals like oats, juicy pearls and more, giving brands the opportunity to create innovative, differentiated, premium product offerings, tailor-made for Indian consumers.

SIG is also developing India-centric solutions to address the needs of smaller dairies and juice brands. The recently launched CFA 1212 filling machine brings the same volume flexibility offered by its high-speed portion pack filler, now at a slower speed of 12,000 packs per hour. With this, SIG enables mid-sized brands to have smaller capacities, as per their requirements, at a more affordable price.

SIG on sustainability

According to the company, sustainability is an integral part of SIG. It has to its credit a host of industry firsts — sourcing 100% of its renewable paperboard from FSC-certified sustainable forests, using 100% renewable energy to produce all its carton packs, and creating the world’s first aseptic carton pack without aluminium foil, the world’s first paper straw for aseptic cartons and the first carton linked to only renewable materials, to name a few.

For SIG India, sustainability has meant close engagement with industry groups like the Action Alliance for Recycling of Beverage Cartons (AARC) and with Government bodies, to increase the collection and recycling rates of used beverage cartons. SIG India also currently offers its customers paper straw solutions as an alternative to SUP and is committed to work with the industry to help optimise the cost of these solutions, and in future, develop local options for customers.

SIG India's growing customer base and wide range of packaging SKUs bear ample testimony to the success it has seen so far in this market. As such, for SIG India, this is just the start — the commitment to India is clear, and the company is now focused on delivering on its plan for growth.

Surat printers launch web-to-packaging platform, Turtle Boxes

Rahul Kumar — Tue, 22 Feb 2022 16:49:00

Both Shah and Jain are in commercial and packaging printing. They said the primary focus of Turtle Boxes is to provide the best printed quality mono cartons and shipping boxes for small and medium startups and brands.

“Now, customers can order a minimum of 25 boxes of a single design and SKU. If they don't want a printed one, they can also order plain boxes to pack their stuff and sell in the market,” Shah and Jain said.

According to Shah and Jain, the idea behind Turtle Boxes is that it wants to end the struggle of businesses and individuals who don’t want to visit a printing press with in-person orders and spend their time in the printing press.

“During trial and beta testing, we have received amazing responses and orders from the online packaging designers and buyers,” Shah and Jain said. “We will extend our offerings with labels/stickers and carry bags. Soon, we will make it a one-stop solution for cosmetics, bakery, food and other startups.”

The Turtle Box backend technology, PackQ, is being developed by CloudLab, a pioneer in building web-to-print, web-to-pack and web-to-labels. The CloudLab AG Technology Distribution is handled and sold in India by Dezmark Automation.

Kohli Industries completes 50 years

Rahul Kumar — Fri, 18 Feb 2022 09:00:00

During the first decade (1972-1982), Kohli focused intensely on the domestic market in India, carefully developing a strong reputation for its products and services. After securing a large market share in India, by mid-nineties, Kohli diverted its attention to exports. With the ability and focus to offer efficient and well-designed machines with an emphasis on customer care, Kohli witnessed exponential growth within the first two decades of business. By 1990, Kohli Industries inaugurated a state-of-the-art facility dedicating a huge investment to research and development. As of 2021, Kohli has successfully installed more than 1,500 machines in 36 countries.

“It has been a beautiful and productive 50-year journey for Kohli Industries,” said Kuku Kohli of Kohli Industries.

Kuku Kohli of Kohli Industries

By the time Kohli joined the family business 15 years after its establishment, the company had already established a strong domestic presence and were focused on gravure presses, laminators and slitters for the flexible packaging industry.

“In 1990, I visited Drupa for the first time. It was a crucial turning point for me that paved the future for Kohli. I was in awe of the technology being displayed at the show, and at the same time could see the disparity between European and Indian machine manufacturers. At the age of 22, it became my mission to reduce this gap and to gain international respect that I was confident an Indian manufacturer could achieve,” Kohli said.

His father had secured a large market share in India, but Kohli’s intention was to grab the international market by offering innovative machines at competitive prices with a strong emphasis on personalised customer service.

He added that Thea-9one8 has been a game-changer, bringing Kohli as a manufacturer to the forefront. The company is proud to be the first Asian manufacturer to have demonstrated live, printing speeds of 651-mpm using toluene-free inks and 501-mpm using water-based inks.

Kohli offers a wide range of gravure printing presses to suit different applications -- the Rhea series with mechanical line shaft drive and Thea series with electronic line shaft drive.

Besides gravure, the company also offers Plutus, a multi-process and multi-technology coater-laminator; Gaia, a simple solution to solvent-free lamination; Athena, an advanced solution to solvent and water-based lamination or coating; Lamex, an extrusion coating and lamination machines, manufactured in partnership with Rajoo Engineers; and Zeus, an innovative range of slitter-rewinders for the flexible packaging and pressure sensitive label industry.

Kohli said all the machines were conceptualised by machine operators, for machine operators.

“With the help of an incredible team, a supportive family and determination, 32 years since the first Drupa visit, my dream has finally come true. I believe there is a new-found appreciation and acceptance for Indian machines that was absent before. We are now favourably compared with our European counterparts,” he concluded.

UFlex invests in Kodak Flexcel to drive expansion

Rahul Kumar — Fri, 11 Feb 2022 10:54:00

Parwez Izhar, CEO, cylinders business, Uflex, said, “For our in-house packaging printing, Flexcel NX plates enable us to convert an increasing number of jobs from gravure to flexo; underscoring our commitment to produce sustainable flexible packaging without impacting on quality. We also expect to see additional benefit from quicker makeready times and minimising wastage by coming to colour quicker.”

He added that the “simple but robust technology portfolio from Miraclon is another big advantage. With Flexcel NX plates, we are able to optimise inventory management and can concentrate on all the different benefits we can achieve with one plate instead of having to use different plates for different jobs.”

The company’s platemaking division also supplies to trade shops and other converters in the region. Izhar concludes, “Many of the companies we supply plates to have been requesting Flexcel NX plates to help them realise better on-press efficiency without impacting the quality of print produced — it’s really been established as the technology of choice for wide web flexible packaging printers. With our own Flexcel NX System up and running we can meet that demand and demonstrate its benefits to other customers too. A win-win for everyone.”

Chiripal Poly Films completes 10 years

Rahul Kumar — Fri, 28 Jan 2022 16:48:00

“As I look back on this incredible journey, I get a sense of fulfillment,” said Sumant Singhal, CEO, Chiripal Poly Films, “On this day, 10 years back, we started with a dream in our hearts. We were the newest kid on the block in an industry where skeptics had written us off.”

He added, “Today, we stand at the cusp of another decade of growth driven by our soaring ambition and our robust expansion plans. We, at Chiripal Poly Films, have always ensured that our growth and prosperity should positively touch the lives of all our stakeholders. This will be our endeavour in the coming decade as well. We believe this is the only way to make growth meaningful, fulfilling and sustainable.”

Founded in August 2009, Chiripal Poly Films started production operations in January 2012 by installing its first production line of BOPP films with German technology in Ahmedabad. A leading manufacturer of flexible packaging solutions, the company produces biaxially-oriented polypropylene (BOPP) films, biaxially-oriented polyethylene terephthalate (BOPET) films, and PET resin chips.

In the last 10 years, the company has established a good reputation in terms of products, quality and services; not only in the domestic market but internationally as well. The state-of-the-art high-performance lines enhance its capability to fulfill customers’ needs and fosters the development of new customised films for different applications and tailor-made products.

Chiripal Poly Films currently has three BOPP lines, one BOPET line, and one offline coater with a total production capacity of 118,000 MTPA and five metallisers with installed capacity of 52,000 MTPA.

On the rigid packaging segment, the company expanded into backward integration by installing a PET resin manufacturing unit with 2,20,000 MTPA production capacity. The state-of-the-art resin plant is capable of producing bottle, textile, and film grade resins, which ensures timely supply of raw material to the BOPET film plant, and allows serving other plastic segments, such as water and carbonated drinks packaging, and textile processing.

The company has recently started a new plant at Hyderabad to cater to the burgeoning demand in the South Indian markets.

The Hyderabad plant is equipped with a 10.4-m BOPP line with a production capacity of 55,000 MTPA. Additionally, one BOPET line of 8.7-m 45,000 MTPA production capacity and one CPP line of 5-m width and 19,000 MTPA will start soon. The BOPET line is under commissioning and will be operational by May 2022, while the CPP line is expected to be commissioned by the end of the year. The capacity of the Hyderabad plant will reach 119,000 TPA, and will have three metallisers of 35,000 TPA.

“Considering the width of the new BOPP 10.4-m line, our intention is to orient the production to thicker micron films. In fact, the line will be capable of producing from 10 to 70-micron BOPP films. Furthermore, it will have a flame treatment facility which will allow us to guarantee retention of dyne level for a longer period which would help us serve our customers efficiently,” the company told WhatPackaging?.

Chiripal has high-quality standards certifications on quality management systems and food contact packaging. It is certified by AIB, BRC rated AA, ISO 9001, ISO 14001 and OHSAS 18001.

Chiripal Poly Films is part of Chiripal Group, a multi-faceted business conglomerate founded in 1972. Chiripal Group has a current annual turnover of approximately USD one-billion from various businesses, including textiles, petrochemicals, flexible packaging, education, and infrastructure.

Hubergroup announces global price rise

PrintWeek Team — Mon, 30 Aug 2021 11:23:00

The firm said the printing ink industry had been severely affected by the rising cost of transport and of key ingredients including pigments such as titanium dioxide, as well as resins and solvents. It said it had been forced to act with worldwide price rises as a result, despite trying to source alternative raw materials and exploring other sourcing methods.

CEO Heiner Klokkers said that customer satisfaction was a top priority. “To ensure that we can continue to offer them high-quality printing inks and raw materials in the future, it is unfortunately essential in the current situation that we reflect the significantly increased procurement costs in the prices of our products,” he stated. “Our field staff around the world will shortly be informing customers personally about the specific effects and is of course available to answer questions at any time."

(Courtesy: PrintWeek.com)

Nestle’s popular brands to sport masks on packaging to spread awareness

Abhishek Muralidharan — Sat, 21 Aug 2021 11:24:00

Nestle is tweaking its product packaging to leverage the power of iconic brands like Maggi, KitKat, Nescafe and Everyday to deliver the message, said Nestle India in a statement. The company will have a campaign in print and digital media informing its consumers about the packaging changes, generating awareness, said a Nestlé India spokesperson.

“Nestle India understands the need of the hour and wants to sensitise each and every individual about the one basic practice that we must all follow — masking up," the statement said.

The company has taken this step amid experts saying the rise in fresh cases and the R-value in many states are a worrying sign.

“To remind all of us and to create awareness on this very important safeguard, we have commenced work towards tweaking our product packaging that will see our iconic brands 'masked up'. Our aim is to ensure that this important message gets reinforced every time when consumers look at our products," he said. By leveraging the power of iconic brands, Nestle aims to spread even greater awareness on the importance of masking.