New integrated high technology plant outside BengaluruRajhans’ structured expansion in flexible packagingRajhans Enterprises is one of the largest commercial sheetfed and web offset printers in India. For over three decades, Rajhans has been the leading printer of periodicals – 45 monthlies, six weeklies and plus a raft of daily newspapers from three locations.
The outside view of Rajhans’ new plant in Bidadi on the Bengaluru-Mysore roadThe showpiece production assets – an F&K 8-color wide web CI flexo press and a 5-layer Macchi extrusion blown film line accompany an Expert gravure press, solvent-based and solvent less laminator from Expertand 3-side sealing machine, stand-up seal and centre seal and slitting machines from SP Ultraflex. Hence, covering the complete workflow from design, prepress to printing and postpress the new plant is completely integrated and self-sufficient except for flexo plates and gravure cylinders.
Rajhans’ Akash Balachandra says, “With the goal to focus on the flexible packaging segment, we planned to come up with a new plant. It has the capacity to print around 350 tonnes a month on various polymer and paper substrates and now as a company we are a one-stop solution for all product segments including magazines, newspapers, cartons, labels and flexible films and laminates – that is for the periodical, commercial and for the packaging segments. The whole operation is modernized,comprehensive and automated with the latest technology and complete prepress, press and postpress infrastructure.”
Rajhans’ new 1,300 mm-wide F&K 20SIX CI flexo press is the flagship of its packaging fleet. It’s features include improvements in printing quality, ease-of-use, versatility and efficient use of space. With the use of servo drives, accurate registration can be achieved across the 8 printing units. The print width is 1,250 mm while material width varies from 650 mm to 1,300 mm. Since, print length, pattern, ink and printing carrier are factors that count for printing speed, the maximum printing speed of 400 metres a minute can be achieved when using the largest possible plate cylinder circumference.The press can print on a wide variety of materials including extensible substrates such as LDPE from 25 to 350 microns in thickness, HDPE from 10 to 165 microns, PET from 8 to 80 microns, PP from 15 to 250 microns, OPP, BOPP, COPP from 10 to 95 microns, PVC from 12 to 185 microns, PA from 8 to 30 microns and paper 40 to 95 gsm with solvent-based inks.
The modular design of the new CI flexo press makes it user friendly and easy to maintain. Bobst’s smartGPS reduces the makeready time from the hours to minutes, thus reducing the production cost.
Food safety management
Rajhans’ plant is ISO 22000 certified for food safety management standards that help organizations identify and control food safety hazards; ISO PAS 223 certified for Food Packaging Material Manufacturing; ISO 9001: 2008 certified for quality management system; SEDEX 4 pillar for supply chain; and, Agmark certified by the Government of India for agricultural products.