The robotic laser engraving line has reduced the cumbersome process of manufacturing rotogravure printing cylinders to a single operator job. This automation however poses absolutely no threat to the current manpower as there exists a separate well contoured market segment for conventional electro-mechanically engraved, embossed, coated rotogravure printing cylinders much like the laser robotic plant engraved rotogravure cylinders. While over 200 cylinders are manufactured per day using the conventional process at Uflex, through the robotic laser engraving line spread in approximately 1/10th of the entire cylinder manufacturing shop floor area at Noida, a single operator can produce additional 60 cylinders per day.
Major advantages associated with the rotogravure cylinders manufactured on the fully automatic robotic laser engraving line are:
- Consistency in printing for flexible packaging;
- More mileage from the cylinder;
- Less ink consumption during printing operation as compared to conventional electromechanical engraving;
- Production volumes have gone up from the erstwhile 180 cylinders per day to produce 240-250 cylinders;
- The cylinders produced are dynamically balanced and can run up to a speed of 500m/minute;
- High Definition image re-production capability of 6,400 DPI which is not attainable through the conventional electro-mechanical engraving process;
- Very less production space is required in comparison to the conventional process with similar production capacity;
- Requires less power, hence the running costs are low.
Expressing delight on this feat, Mr. Ashok Chaturvedi, Chairman &Managing Director, Uflex Limited said, “For this ambitious project we decided to partner with M/s Think Lab, Japan because of their unmatched technological finesse in gravure printing technology which is globally acclaimed. It is a name that instills trust and confidence and thus serves to be a perfect strategic partner for Uflex for our cylinder manufacturing business. We are getting online real time service support and assistance from Think Lab which is now completely dovetailed with our operations and ensures practically zero downtime. Our precision has improved manifold so has the production efficiency.”
Uflex is India’s largest end-to-end flexible packaging company and an emerging global player. Since its inception back in 1983, Uflex has grown from strength to strength to evolve as a truly Indian Multinational with consumers spread across the world. Uflex today has state-of-the-art packaging facilities at multiple locations in India with installed capacity of around 100,000 TPA and has packaging film manufacturing facilities in India, UAE, Mexico Egypt, Poland and USA with cumulative installed capacity in excess of 337,000 TPA.
All Uflex plants are accredited with ISO 9001, 14001, HACCP & BRC certifications. Uflex caters to markets spanning across the globe in over 140 countries like USA, Canada, South American countries, UK and other European Countries, Russia, South Africa, CIS, Asian and African nations. Integrated within its core business profile are allied businesses like Engineering, Cylinders, Holography and Chemicals which further give Uflex a superior edge above competition.
Uflex Limited is also a part of the D&B Global Database and winner of various prestigious national and international awards for its products’ excellence. Uflex offers technologically superior packaging solutions for a wide variety of products such as snack foods, candy and confectionery, sugar, rice & other cereals, beverages, tea & coffee, dessert mixes, noodles, wheat flour, soaps and detergents, shampoos & conditioners, vegetable oil, spices, marinates & pastes, cheese & dairy products, frozen food, sea food, meat, anti-fog, pet food, pharmaceuticals, contraceptives, garden fertilizers and plant nutrients, motor oil and lubricants, automotive and engineering components etc.
Some of Uflex’s clients on the global turf include P&G, PepsiCo; Tata Global; Mondelez, L’ Oreal, Britannia, Haldiram’s, Amul, Kimberly-Clark, Ferro Rocher, Perfetti, GSK, Nestle, Agrotech Foods, Coca-Cola, Wrigley, Johnson & Johnson among others.