Roto Master doubles engraving capacity

Strong flexible packaging growth drives cylinder demand

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Capacity overhaul in the very first year
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.

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