Roto Master doubles engraving capacity

Strong flexible packaging growth drives cylinder demand

186
Roto Master
YU Reddy, CEO and Sanchit Bansal, partner, Roto Master India, at their plant in Ballabhgarh, Haryana

Roto Master was established in May 2016 by an experienced team of industry professionals, including YU Reddy, the company’s CEO, a veteran of the cylinder-making industry. Roto Master is gaining in reputation for manufacturing quality cylinders for gravure printers which are mainly used for the fast growing flexible packaging. The company is already producing over 800 cylinders a month which it supplies to customers all over the country. Packaging South Asia met YU Reddy and Sanchit Bansal, director of the company, at their plant in Ballabhgarh, Haryana to catch up with progress made by this new company and
how it looks at the future.

Capacity overhaul in the very first year

Rotomaster2
In addition to flexible packaging gravure printing also covers different substrates like PU leather, sunmica, vinyl, wallpaper and others

Roto Master initially installed two Hell electronic gravure cylinder engraving machines but soon realized that this capacity wasn’t enough to meet the fast-growing demand for cylinders. Already inundated with orders in just their first year of operation, the company commissioned their third engraver, a Dynamic Motivated Alliance (DMA) engraving machine, a German technology machine marketed from Taiwan. Highly impressed with the features and performance of this electronic engraver, Reddy has already ordered another DMA machine which will be the company’s fourth engraver installed in the space of just over a year.

Reddy spoke of some critical parameters which he says are the reasons why he prefers the new DMA engraver. To begin with, it is about 30% faster and has a much better engraving head and offers better text enhancement. It uses open source software for the entire process and works equally well on Mac and other computer platforms. Besides, it uses PDF imaging, which Reddy says is better for text clarity as compared to TIF files.

Cylinder-making process

Reddy says that he was among the pioneers of electronic cylinder engraving in India following his training in Ohio, in 1990. He explains that the process of cylinder-making starts with the design reference that is provided by the customer. It includes the design layout, color separation, color resolution, color application, color correction, font selection, and other aspects of the design. Thereafter, all the customer’s inputs are integrated in the dimensions of the cylinder, and sent back as a PDF file to the customer for approval.

After approval, the actual process begins with the manufacture of the base shell which is normally made of mild steel cut and rolled to size. Alternatively, prefabricated pipes meeting the required dimensions of the cylinder are used.

This basic structure then undergoes a process of grinding till it is ready for nickel-plating, followed by copper plating on which the engraving takes place. Finally, the cylinder undergoes chrome plating, which marks the completion of the process. In terms of scale, if one job is to be printed in eight colors, eight cylinders would have to be manufactured. Reddy explained that several layers of plating are necessary as mild steel does not bond well with copper although nickel bonds well with both mild steel and copper.

Roto Master cylinders enhance food safety

Roto Master cylinders plays a part in improving safety standards in the packaging industry. Reddy says, “As a cylinder maker, we have to study the packaging substrate (film or laminate) well because the design of our cylinder is based on what that substrate is going to be. While developing a design we have to remind the printer about certain government norms, especially end user guidelines like disposal of the plastic package and some others. These user guidelines should also be engraved on the cylinder so that they get printed on the substrate which could be the package itself or a separate label that is pasted on the package. The role of cylinders has a major impact on product labeling, especially in food packaging.”

Reddy further said that it is not just the substrate that Roto Master needs to know before making a cylinder, but also the ink that would be used on the substrate. This is a mandatory requirement that the customer must comply with. The kind of substrates and solvents used by many printers do not often meet the standard requirement.

The impact, resilience, and growth of responsible packaging in a wide region are daily chronicled by Packaging South Asia.

A multi-channel B2B publication and digital platform such as Packaging South Asia is always aware of the prospect of new beginnings and renewal. Its 16-year-old print monthly, based in New Delhi, India has demonstrated its commitment to progress and growth. The Indian and Asian packaging industries have shown resilience in the face of ongoing challenges over the past three years.

As we present our publishing plan for 2023, India’s real GDP growth for the financial year ending 31 March 2023 will reach 6.3%. Packaging industry growth has exceeded GDP growth even when allowing for inflation in the past three years.

The capacity for flexible film manufacturing in India increased by 33% over the past three years. With orders in place, we expect another 33% capacity addition from 2023 to 2025. Capacities in monocartons, corrugation, aseptic liquid packaging, and labels have grown similarly. The numbers are positive for most of the economies in the region – our platform increasingly reaches and influences these.

Even given the disruptions of supply chains, raw material prices, and the challenge of responsible and sustainable packaging, packaging in all its creative forms and purposes has significant headroom to grow in India and Asia. Our context and coverage engulf the entire packaging supply chain – from concept to shelf and further – to waste collection and recycling. We target brand owners, product managers, raw material suppliers, packaging designers and converters, and recyclers.

In an admittedly fragmented and textured terrain, this is the right time to plan your participation and marketing support communication – in our impactful and highly targeted business platform. Tell us what you need. Speak and write to our editorial and advertising teams! For advertisement ads1@ippgroup.in , for editorial info@ippgroup.in and for subscriptions subscription@ippgroup.in

– Naresh Khanna

Subscribe Now