Zircon Technologies marks a quantum leap

-poised to conquer new horizons in flexo printing with EskoArtwork

Being on expansion drive, Zircon Technologies India Ltd opted EskoArtwork’s CDI Spark 4835 high- definition imager for Flexo, with the unique in-line UV (main exposure) to boost quality, consistency and enhance productivity.

Zircon, a pioneer in high quality flexo label printing in South Asia, started implementation of high print resolution of 150 lpi and 175 lpi during their initial days of business from 2006 onwards. Increased growth in the packaging industry encouraged Zircon to expand their existing setup. A new sprawling factory is being constructed in the industrial area of Dehradun, very close to their existing operations. A 10-colour brand new flexo press is being added alongwith a complete in-house prepress workflow and CDI Spark 4835 hi-definition imager with in-line UV technology. Zircon has also finalized their plans to expand to other locations in India including Mumbai and Chennai and they have already chosen EskoArtwork for complete prepress integration at both sites. Besides, Zircon has planned to venture into the offset folding carton segment and EskoArtwork again remains their preferred prepress partner.

“Zircon has always focused on business driven by customers and invested regularly in the best of technology available to serve their customer better. Zircon’s dedication combined with technical expertise of EskoArtwork’s team is ready to conquer new horizons in flexo printing. The technical expertise of EskoArtwork and printing capabilities of Zircon is completely ready to go beyond the boundaries and limitations of flexo printing,” commented Sanjeev, director – operations.

“Zircon selected EskoArtwork as we offer complete solution – hardware, software and expert services. I am confident the EskoArtwork teams of flexo experts will provide necessary know-how to support Zircon’s vision of growth. We‘re very happy to welcome Zircon team to our growing EskoArtwork customer base in India,” added Dinesh Chandra, MD – EskoArtwork India.

New generation of packaging solutions

-making counterfeiting much more difficult, no chance for pharmaceutical cheats

While to get rid of rapidly increasing counterfeiting of medicines across the world, researchers are developing authenticity seals and security codes intended to make drug packagings uniquely identifiable, manufacturers of machinery and systems will present their track and trace solutions to fulfill the requirements, at interpack 2011, one of the most important events in the worldwide packaging sector, to be held in Dusseldorf, Germany from May12-18, 2011.

Buying Sinupret sinusitis tablets from pharmaceuticals producer Bionorica, anyone will now look on the folding carton a three-dimensional, optically variable, embossed mark, which can be seen in relief when the carton is tilted. In view of the fact that the herbal medicament was so often copied, Bionorica engaged the Munich company Giesecke & Devrient, which specialises in printing bank notes, to design this tangible security feature for Sinupret. Artur Theis, a subsidiary of the Edelmann Group, developed the production process for the new packaging. The mark is printed and embossed by Braun Pharmadruck – also an Edelmann subsidiary – in Bitterfeld. Sinupret, one of the most popular products on the cold treatments market, is just the start: by the end of 2011, Bionorica intends to emboss the packagings of all its product ranges with the new quality seal. “We want to provide the best possible safeguards for pharmacies and users,” says company head Michael Popp.

Producers who have problems with counterfeiters must make their products uniquely identifiable. This is especially true in the pharmaceuticals sector. Although producers of pharmaceuticals suffer losses amounting to billions of euros each year through product piracy, this is not the main problem, for counterfeit medicines threaten the health or even the lives of unsuspecting patients.

Experts confidently expect the track and trace system to be implemented throughout Europe in the near future. “The EU’s pharmaceuticals package could become law soon,” says Dörstelmann. Manufacturers of machinery and systems are well prepared for a switchover. Optima Group Pharma, for example, based in the Swabian town of Schwäbisch Hall, specialises in filling and sealing syringes and vials. It already offers, on request, coordinated track and trace solutions for producers of pharmaceuticals. “Ready-to-use syringes are stored and transported in special syringe nests in plastic boxes referred to as tubs. Our machines label the containers, so that they can be traced at any time,” explains company spokesman Henning Felix. Bosch Packaging Technology, which supplies filling, processing and packaging technology for the pharmaceuticals industry, also has printing and tracing equipment in its portfolio. Within the printing module, each minute, up to 400 folding cartons are transported on a conveyor belt through a printer, which labels each carton with a data matrix code containing a production number, use-by date and serial number. A camera subsequently checks and verifies the code. The data are finally stored on a high-capacity central server, from which they can always be called up. If a product that cannot be identified in this way turns up in a pharmacy, it must be a counterfeit.

It is unlikely that pharmaceuticals counterfeiters will be attracted by medicaments that have been provided with a security mark, a code and a top quality packaging. However, there are still many obstacles on the path to obtaining maximum patent protection. An enormous investment is required in order to retool packaging lines, and this could prevent pharmaceuticals companies from acting quickly.

manroland to aggressively target medium and small printers in India

With a wide range of printing technology solutions tailor made for the Indian market, manroland India is well equipped to capture a larger share of the pie, and will increasingly focus on small and medium size companies. This was conveyed by Rafael Penuela Torres, executive vice president-sales, manroland AG in an interaction with SK Khurana, editor, Print & Publishing, on the sidelines to the plant inauguration of Mass Packsols Pvt Ltd in Vadodara (Gujarat).

Talking on the subject of progress made so far after having established their own India office three years ago, Rafael confirmed his happiness over the initiatives taken. Nevertheless - ‘Never is enough’. The overall concept adopted has been to go beyond the ‘just selling the machines’ concept and be on their own with Indian expertise. Selling the presses is easy, but helping printing companies differently has been one of their motives and efficient after sales service is part of that.

Commenting on the next year targets, Rafael informed that they will be expecting fifty percent more unit sales and said, “Our immediate programmes in serving our existing customers better, regular visits by our service staff is on the cards. These visits termed as ‘Clean Desk Meetings’ shall be covering two ways: the first being, to study the utilisation of the machine’s capabilities fully or not, and if not, helping the printers in this direction; and the second one to motivate our customers to opt for maintenance contracts so as the machines remain working all the time with least stopping. This type of maintenance contracts shall altogether be different from extended warranties which have been the preferred choice till date.

Divulging more in details, the impact of manroland’s new re-structuring/stand alone policies announced recently and specifically on Indian printing companies, Rafael stated, “There has been discussions/rumours as manroland moving towards mergers/acquisition/co-operation concept in the last eighteen months. But having decided by their investors/board members very clearly that manroland has to proceed on its own, utilising its existing strengths and achieving new targets, grow together internally and externally and at least try to come back to the level of 60-70 percent of sales revenues of the year 2007 in next one to two years. Re-structuring is also newer step planned as regards to their manufacturing activities spread at multi locations. Consolidating these plants in such a way shall mean that manroland is going to have one facility to manufacture components for sheetfed and web-presses simultaneously and assembling activities in separate locations. This decision will bring more efficiency that too economically.”

“Printing as such need not be termed as ‘commodity’ but as a ‘value added concept’, customized configured to develop a new market like incorporation of inline foiler,” mentioned Rafael. Other important steps to be taken by them for Indian market shall include ‘targeting each customer differently’.

Despite the company’s new measures leading to reductions in employees by about 10 percent by the end of the year 2012, the more people will be appointed for manroland operations in India. “We believe in ‘TOP’ (Technology, Organisation, and People) concept, providing 360 degree consultancy for performance improvement,” concluded Rafael who was on his visit to Latin America, India and China. Rafael also did not forget to mention that India is very price conscious market way ahead to China. Printers here do not want prefer highly configured machines and as such require to be treated differently than rest of the world.


MASS Packsols born for printing with ambitious goals

- equipped with state-of-the-art printing equipments for packaging from manroland and Bobst

Winners make every movement sagaciously, observing all potentials in a comprehensive manner. So did Moni Patel, CEO and managing director of MASS Packsols Pvt Ltd under the astute guidance of his father Arvind Patel who is already in business of developing infrastructure and now also has the responsibility of director at MASS Packsols, with constructive support from technical consultant Anil Suthar, while establishing the new company dedicated to provide top quality packaging solutions, especially to pharmaceutical companies. Equipped with Roland 706LV HiPrint and Roland 505LV from manroland, their state-of-the-art facility located around 35 km away from Vadodara (Gujarat) at Gandhara village was recently inaugurated marking the venture of one more entrepreneurs’ family into printing industry. Here’s a brief.

The establishment of MASS Packsols Pvt Ltd with initial investment of over Rs 50 crore is a good sign for Indian print industry showing the new generation of entrepreneurs having no printing background also entering print and packaging segment of the industry, which shall innovatively energize the entire print community in a big way. Before starting the company, intensive home work was made to explore the better business opportunities for the young beginner from this Patel family of entrepreneurs. “Initially, we were to set up a pharmaceutical firm in Vadodara, and for the purpose we purchased a big piece of land to start operations in an open space, market survey had already been done along with taking preview of required machinery and raw materials. But while identifying the packaging solutions providers for our proposed products within and surrounding region of Vadodara, we faced limitations regarding quality. It was the point which changed our mind and we started to ponder over print and packaging segment ourselves and closely observing the practicalities and potentials, we finally decided to establish MASS Packsols Pvt Ltd procuring the equipments of top-of-the-line brands,” divulged Moni Patel, exclusively talking with SK Khurana, editor- Print & Publishing, who also joined the happy moments of inauguration.

Formal inauguration awaited by eldest family member of Mass Packsols.Spreading over few acres of land and equipped with cutting-edge machines Roland 706LV HiPrint and Roland 505LV from manroland and high-end post press and finishing solutions such as three die cutting machines, two units of gluer and paster, and window patching liners from Bobst, the state-of-the-art facility of MASS Packsols was formally inaugurated by Ranjan Patel’s mother in the august presence of over 500 invitees including Rafael Penuela Torres, executive vice president-sales, manroland AG; Leopold von der Gabelentz, executive delegate India, manroland AG; Anil Bhatia, managing director, manroland India Pvt Ltd; Subhasis Roy, business director SEA, India, Mideast & Africa, business unit sheetfed, Bobst SA, etc.

With the ROLAND 700 HiPrint, the universal medium-format press, manroland offers the ideal production instrument for value added printing. With the optional maximum speed of 17,000 sheets/hr, it is one of the fastest presses in the market, uncompromisingly designed to produce the high printing quality. The modern principle of double-diameter impression cylinders and transferters provides gentle sheet travel for substrates up to one millimeter thick. The ROLAND InlineObserver enables the printer to monitor sheet travel and thus makes sure the settings are always optimal. Even at high press speeds, the AirGlide delivery produces perfectly even stacks due to the particularly flat sheet ascent and long sheet stabilization path. A host of QuickChange options reduce make-ready times by as much as 40 percent compared to standard presses. With extremely precise chambered doctor blade system, the coating layer is metered exactly in the highest quality even at high production speeds.

Inauguration in progress by Rafael Penuela Torres, EVP-sales, manroland AG.While with speeds up to 18,000 sheets per hour, the ROLAND 500 ensures exceptional performance delivering outstanding printing quality. The center points of the double-diameter impression cylinders and transferters are arranged virtually in a line to provide the world’s flattest sheet travel from the feed-board right through to the delivery pile. In addition to automatic substrate thickness adjustment, there are three different height settings for the transferter gripper bars. As a result, sheets from 0.04 to 1 millimeter are always transported through the press gently and contact-free over the air tracks. The massive integrally-cast base frame guarantees precise register. This combined with the stable mountings ensures smooth running for the lifetime of the press, and the double-diameter impression cylinders and transferters reduce the number of sheet transfers and thus the risk of register problems. Team manroland at the inauguration ceremony.The fast-reacting 16-roller inking unit with large storage capacity provides an outstanding printing quality – with consistent inking over the entire run. And the Deltamatic damping unit eliminates the need for mechanical hickey pickers which avoids any loss of quality and reduces the number of waste sheets. The unique positioning of the chambered doctor blade system at the delivery side of the coating module prevents splashes and foaming from impairing printing quality.

“Auspicious beginning of MASS Packsols shows the strength of Indian print and packaging market. We are pleased having one more valued customer in India in form of MASS Packsols installing our two high-end machines in one go which would ensure remarkable success for them,” commented Rafael Penuela Torres.


Pramod Engineering: committed to facelift binding process

New Delhi-based Pramod Engineering (PEW) has endeavoured to ease and speed up the process of binding magazines, newspapers, printed products, text-books and note books. Printers are able to meet a deadline with high speed binding solutions. Machines from PEW have been installed with most major presses all over the country. Since these binding machines are not configured or attuned to a specific printed product, they offer flexible integration and product handling capability. Their all machines are now PLC controlled.

A sister concern of Delhi Press Magazines group and founded by its managing director Naresh Nath, PEW is now spearheaded by Divesh Nath and Rohit Nath. Delhi Press produces 2.3 million magazine copies a month and its in-house production gives great strength to Pramod Engineering into researching the binding machines.

The six products that PEW manufactures are: Flowline, Side Gathering, 3-Knife Trimmer, Web Stacker, Double Head Saddle Stitcher, and Paper Drilling.  Flowline is a 8000 cph production line for six-head saddle stitching with in line auto form feeder, reject copy ejector and three-knife trimmer. Copies of up to 500 mm spine length, center stitched can be produced. Twelve auto-feeders for printed forms can be used at one time. Copies are made untouched right from the feeding of forms to three-knife trimming, making the Flowline best for magazines, note books and text books.

Side Gathering operates at 5000 copies per hour and collates book blocks with an online two head stitcher. The machine can be extended for up to 24 stations. The book blocks can then be transferred to perfect binder or thread sewing. Newly introduced 3-Knife Trimmer is a heavy 5.5 ton machine that has 25 cycle per minute operation and can accommodate pile height of

80 mm per cut. Suitable for collecting printed forms of running webs, Web Stacker decompresses air making the forms fit for stacking and automated binding. Double Head Saddle Stitcher is a two-head, 4000 cph center stitcher. Suitable for high production manual feeding jobs, it is a good replacement for local hand held stitcher for its speed, accuracy and neatness of the stitch. Whereas Paper Drilling drills up to four holes at high speed and variable size up from 4 mm in a ream of paper.

During the year 2010, the company supplied around 28 large binding machines installations in India, Nepal, Nigeria and Sri Lanka. Most of the orders are now repeated with existing customers. The company now has an impressive installation base of 130+ machines worldwide.

Group Publications