Essel Propack increases capacity improves quality with Gallus Labelmaster 440

The Essel Propack team in the Danville, Virginia plant alongside the new Gallus Labelmaster 440 press. Photo Heidelberg-Gallus
The Essel Propack team in the Danville, Virginia plant alongside the new Gallus Labelmaster 440 press. Photo Heidelberg-Gallus

11 August 2020. As part of a plan to expand its production capacity and grow business, Essel Propack, located in Danville, Virginia, installed the Gallus Labelmaster 440 from Heidelberg to satisfy the increasing quality standards in the laminated plastic tubes market. Rebecca Melville reports.

Labelmaster  Expanding Capacity, Increasing Quality, and Productivity

Essel’s Labelmaster, equipped with nine flexographic printing units, guarantees high-quality printing due to precise color-to-color registration – even at maximum speeds of up to 200 m/min. According to Shrikant Jindam, Printing Head Americas of Essel Propack, “Our customers were looking for an option with higher quality, so we knew that Flexo would be our best option. We can run this press at top speeds and not have to worry about the quality lacking.”

With a printing width of 440 mm, the Labelmaster has a wider offering of printing decoration methods for customers, including flexographic, screen, cold foil, hot foil embossing, and metallic doming. The press has an extremely short web path (only 1.4 meters between printing units) and produces minimal waste thanks to the quick set-up times and stable register accuracy.

According to Jindam, “Not only does the ease-of-use impact our productivity day-to-day, but it was extremely easy to learn how to use this machine. It only took three days to train on, and by the end of the week, we were running at full speed – ready to take on new jobs.”

RCS 330: Minimizes waste, reduces changeover times

Alongside the Labelmaster, Essel Propack has a Gallus RCS 330, a flexible, modular inline press with direct drive technology. Individual printing methods on the machine can also be replaced without needing to separate the web. Thanks to the high degree of automation in all modules, the press minimizes waste and dramatically reduces changeover times while giving the flexibility to grow over the years.

“The RCS has been a great machine for our company, so much so that it is our platform of choice for Essel all over the world in different segments of our company,” said Jindam. “We’ve enjoyed partnering with Gallus throughout the years – they have always been supportive and only a phone call away. We look forward to our continued partnership with Gallus and Heidelberg in the years to come.”

About Essel Propack

As the largest specialty packaging global company, Essel Propack, manufactures laminated plastic tubes catering to the FMCG, Pharma, and Cosmetic spaces. Employing over 3000+ people, Essel Propack functions through twenty state-of-the-art facilities and in ten countries – selling circa eight billion tubes and growing each year. As the world’s largest manufacturer of laminated plastic tubes, Essel Propack caters to diverse categories that include brands in beauty and cosmetics, pharma and health, food, oral, and home. While offering customized solutions by continuously pioneering first-in-class innovations in materials, technology, and processes.

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

It is the right time to support our high-impact reporting and authoritative and technical information with some of the best correspondents in the industry. Readers can power Packaging South Asia’s balanced industry journalism and help sustain us by subscribing.

– Naresh Khanna

Subscribe Now


Please enter your comment!
Please enter your name here