Hyderabad-based Pravesha Industries Private Limited (PIPL), incorporated in the year 1993, is a one-stop shop for all printing and packaging solutions for the pharmaceutical industry. The company recently upgraded their plant machinery with the installation of a print inspection machine from Autoprint – the Checkmate 50.
B Sivaprasad Reddy, chairman and co-founder, PIPL says, “We opted for the installation to be able to cater to the growing demands, speed up deliveries and avoid human limitations to check minute print/finishing quality deviations. We are very excited with our investment. Not only has the machine doubled our production of inspected products, it has given a significant boost to our confidence of supplying defect-free products. Most importantly, this machine is used for 100% inspection of cartons for all the parameters, be it text, color, background, color registration, die-cut registration, or Braille. It is helping us a lot in terms of production, delivery schedules and QMS for defect-free output.”
The new system has enabled Pravesha to produce defect-free print products with 100% accuracy. By inspecting print defects and foil errors, the machine segregates the good and defective sheets into different stacks for further analysis. Interestingly, it eliminates expensive manual labor, while enhancing the checking speed and process.
Operating at speeds up to 250 meters per minute, the machine is suitable for thicknesses varying from 180 gsm to 400 gsm. The minimum carton size that the machine can inspect is 100*100 mm while the maximum is 400*500 mm. For sensitive applications, different tolerance levels can be set in different sections to ensure critical defects are rejected through the special scratch & cluster detection method. What’s interesting is that the machine maintains a database of all defective print images for future reference.
As per Reddy, Pravesha Industries procures machines with utmost care by studying all the technicalities, so that they would be able use them to their fullest of capacity. The company is highly satisfied with the performance of the Checkmate 50.
‘Not only has the machine doubled our production of inspected products, it has given a significant boost to our confidence of supplying defect-free products. Most importantly, this
machine is used for 100% inspection of cartons for all the parameters, be it text, color, background, color registration, die-cut registration, or Braille. It is helping us a lot in terms of production, delivery schedules and QMS for defect-free output.
Under the prepress section, the company plans to soon set up a workflow with high-end packaging s/w applications and CtP from a world renowned supplier. In their press section, for labels, the company has a Gallus ECS 340 mm wide, 10-color flexo press, HP Indigo WS4500 digital offset 7-color press, two 330 mm wide 6-color Intermittent LP Label presses and a DGCON 350 mm wide 2-color flexo press.
In the carton section, Pravesha has a Heidelberg CD102+L with 7 colors UV Combi press, a Heidelberg SM 74 plus lamination 6-color press, a Heidelberg SM 74 plus lamination 5-color press, a Heidelberg SM 102 cm 2-color perfector press, two Sakurai 102 cm 2-color perfector presses and two Miller 32 inches 2-color perfector presses. Under foil printing power, the company has two foil stamping machines.
Their postpress division houses two Intergraphic (Prius) 100% label inspection systems, five Slitter rewinders with code inspection and VDP and Flatbed HFS, Flatbed DC with sheeting (offline with second pass registration) in the labels section. Apart from the newly acquired inspection system for carton, they have MK 102 cm auto die-cutters, two BOBST 102 cm auto die-cutters, five manual platen punching machines, a carton sample maker (Plotter) for board and blanket cutting, BOBST Expert Fold folder-gluer, BOBST Ambition folder-gluer, and a Memory folder-gluer. The postpress section of the company is also laced with 10 lines of Vijuk, Herzog-Heymann (H&H) Germany & Pratham special pharma folding machines of various configurations to produce inserts and outserts. Many specialized finishing equipment for foil printing, digital printing, labels and leaflets are also part of the set-up.
In terms of staff recruitment, the company strongly believes in molding fresh talent than bringing in people with bad pre-notion. Hence, recruitment is handled with utmost care and proper training imparted to those who join. Reddy says this approach has helped the, achieve considerable success and today the company has well-bifurcated departments who operate in a 24/6 format.
Pravesha as a company believes that their quality management system (QMS) has a well-established workflow to handle all the processes from enquiries to after-sale service. The company’s clientele focusses on supplies to regulatory market customers as they produce high quality pharma packaging materials for both primary and secondary packaging like foils, cartons, labels, inserts and outserts, HDPE drums, HDPE bottles (containers), and closures. The company has recently expanded into the food and FMCG packaging products, with clients such as Aurobindo Pharma, Dr Reddy’s, Mylan, Hetero Drugs, GSK, Pfizer, ITC,
Gland Pharma, Glenmark, Ravi Foods (Dukes), Himalaya, Bakers Condiments, and Bluemoon