Rajesh Chadha; From small beginnings to big success!

Rajesh Chadha; From small beginnings to big success!

 The history of Rajesh Chadha, Managing Director of Update Prints Pvt. Ltd., which owes its inception and inheritance to P C Chadha & Co. started by his grandfather, is an interesting one. The first thoughts on letterpress, managing waste problems and family support were all highlights along the way that came on a journey from Kobe in Japan to New Delhi in India, following is the Indian Label converter’s history and thoughts for the future.

Update Factory
Update Factory

The very beginning

In the late 1970s and early 1980s driving on the western part of New Delhi’s Ring Road, many factories could be seen from far away. One such tall building was the factory of P C Chadha & Co. in the Naraina Industrial Area with a signboard on top visible from far. Around the mid-1980s when I was a commercial siliconiser selling release papers, I came to know that P C Chadha & Co. manufactured stickers and was a prospective customer. It was then a matter of time before I supplied some reams of release paper to them. During one of my visits to them, I spent two hours discussing why the stickers they were supplying were curling. I was quite naïve then but with time and experience, I have written on my blog a very widely read article on controlling curl. The young man I met was Rajesh Chadha, who was running P C Chadha & Co. and is the present Managing Director of Update Prints Pvt. Ltd. which owes its inception and inheritance to P C Chadha & Co. started by his grandfather.

 Starting up

In 1924, young P C Chadha, living in Kobe, Japan, initiated an enterprise producing paper transfer labels with a vision that branding would be an important tool for sales of any consumer product, label being the face of any product. Sometime in the midst of turbulent times during World War II in 1942–43, P C Chadha decided to return to his homeland in Rawalpindi, then a part of undivided India and now in Pakistan. Little did he realize that in yet another five years he would have to move again! At the time of India’s partition in 1947 he came to Mumbai to set up his production for maintaining continuity in his passion for producing transfers, the labels of that time. Chadha soon came to recognise that the weather in Mumbai was not suitable for his product, and he moved operations to Pune. Before long he was still restless at the location and travelled up North in India to Patel Nagar in New Delhi where he set up his factory on a 150 square yards plot. He initially worked from home and later from his small factory.

As an entrepreneur’s son, the author had seen his father get advertisement boards hand painted by artists for advertising their stationery products. There was no alternative then. When one saw the transfer labels one used to wonder how they could achieve such exquisite printing direct on sewing machines, postal vans, crockery etc. Years later as the label industry was evolving into screen printing, I saw the same exquisite type of printing, which was different from screen printing, in my cousin’s factory making automotive filters. I realised they were using transfer labels like the ones P C Chadha & Co. produced. I was amazed to learn that the process employed by Chadha for printing was lithography. Based on the principle that oil and water do not mix, printing is done using stone blocks. In 1950 P C Chadha was joined in the business by his son Tilak Raj Chadha. They bought a used lithographic printing machine from England to expand their paper transfers business. Evolving further they later shifted to printing on cylinder type printing press using Zinc blocks mounted on wooden bases.

Major changes

Major changes started to happen when P C Chadha’s grandson Rajesh Chadha joined the business in 1976. The same year they moved factory from Patel Nagar to a 600 square yards plot in the nearby Naraina Industrial Area. With Rajesh at the helm, in 1978 he started to produce stickers by the manual screen-printing process. For the next ten years screen printing business became the mainstay for Chadhas. One of the first major decisions taken by Rajesh Chadha was to buy a European automatic Svecia Screen printing machine to print a full 20” x 30” sheet, quite big for that time. The 1990s was a very eventful decade for the Indian label industry. It was the time when many of today’s stalwarts in the Indian label industry became visible. For Rajesh Chadha also, it was time to shed the conventional image and adopt a modern look. It was during this period that the conventional sticker became an engineered label. Rajesh set up Update Prints in 1994 as his flagship venture thereon, gradually taking over all the business of P C Chadha & Co, which was eventually wound up later in 2009. Sensing the need to modernize with faster machines at Update Prints; he bought his first rotary flexo label press, a ”Focus“. There was no looking back after this.

Investments

In 2001 he bought an Orthotec intermittent letterpress at Labelexpo Asia held in Singapore. Two years later he impulsively bought a Rotatek label press displayed at a New Delhi print exhibition, on an immediate payment basis in full, taking his industry colleagues by surprise. Update Prints under his leadership has been acquiring new state-of-the-art equipment at regular intervals. From the single 600 square yards factory the company was soon operating from three different plots, one of 1000 square yards and two of 600 square yards. It was now time to consolidate for a few years. In another strategic move in 2013, Update Prints moved all their manufacturing operations under one roof to a facility admeasuring almost 25,000 square yards in land area and 50,000 square feet shop floor. This exercise required the involvement of a huge amount of money, time, effort and commitment. The land was designated agricultural land. Setting up an industrial project on it was illegal. Many people in the area have done it but Rajesh Chadha is committed to tread the straight path. He got the land use changed to industrial. Any Indian will know the kind of effort and time this takes. Infrastructure was another problem; the nearest power feeder was far away and to expedite the matter of bringing power to the unit, Update Prints had to install 50 electricity poles at their own expense. The approach road to the unit was in shambles, it had to be re-laid at their own expense. Update Prints now employs over 100 workforce and has a total of eight label presses.

Diverse technologies

Reminiscing about his work in the initial days in labels he says, ”The first label that I created was for Yardley Cosmetics“ he further adds that in those days he had bought two Newfoil three station hot-foiling presses. He used to love working with them creating innovative products. It was the most satisfying part for him because he could imagine and then create labels that would get appreciation from buyers. He has over the years equipped Update Prints with diverse technologies in label printing, decorating and finishing. Whether it is offset printed labels printed on his Rotatek Brava or labels created on flexo, letterpress, hot or cold foiling, screen printing, etc. his company is never left wanting for the ability to create. He is proud to say that  “I deliver quality, service and satisfaction to my customers and for this reason work comes to me automatically. I do not have to waste time running after work.” While discussing digital printing I was not surprised that his reaction was similar to that of a larger part of the Indian label fraternity, ”It does not make sense to me at this point of time. I can print good quality short runs cost effectively on offset and letterpress“. A very interesting change that I noted in Rajesh during my talks with him is that he has started to encourage Indian entrepreneurs who have excelled. While most of his equipment is imported yet in recent times he saw the potential in an Indian manufacturer of label presses, Multitec. He was not hesitant and bought the equipment. In fact, he has followed it up by acquiring two more.

Family life

Rajesh Chadha being the elder son in his family, like in most migrant Punjabi families of that time in New Delhi, joined the business while he was still studying. He is an alumnus of New Delhi’s Salwan Public School and later studied commerce in Dayal Singh College for B.Com and finished with a master’s in commerce. His wife Anju is a master’s degree holder in English and takes an active interest in the business. Rajesh and Anju have two children who are both now married. Their daughter Upasna studied at the prestigious London School of Economics and spent time at Oxford University. Son Aditya, like his father, studied commerce from Delhi’s Shri Ram College of Commerce and later completed his MBA in marketing from ”Rutgers, The State University of New Jersey, USA“. Then after a one-and-a-half-year work experience in AT&T in the US, he returned to India to join his father at Update Prints as director. Rajesh fondly mentored him to take charge of this company.

Update Prints’ business has transformed over the years. They do very little transfer labels business now and largely produce self-adhesive labels. Their customers are mostly leading FMCG companies. Ten percent of their produce goes into export. While in Patel Nagar, waste management was a big problem for them. With the company growing continuously, disposal was becoming a gigantic issue. It was one of the reasons besides expansion that they moved to this present location some 35 Kilometers from Delhi. Here they have developed collectors who take the waste and convert it for various usages and applications. He strongly feels someone needs to work in the direction of managing or recycling this waste effectively and believes a solution will evolve. He also feels going linerless is also a good direction but like digital printing it will be some time before this technology becomes adaptable extensively.

 Rajesh Chadha is satisfied about the time he has spent in the label industry, he says, ”It is an interesting industry. There is lot of work and room for creativity and innovation“. He is proud of his achievements. He has led the company to consistently achieve an almost 20% per annum growth rate, which is above the perceived industry rate. He is beaming when he says, ”Growth comes naturally to my company because of the quality of our work. It is not fueled by huge borrowings from banks“. No wonder he heads a fully family owned successful and growing zero debt company!

 Written in May 2014 and updated in April 2024.

Jandu’s 3rd generation inducted, initiates makeover!

Jandu’s 3rd generation inducted, initiates makeover!

Prabhjot Singh Jandu is the third generation of Jandus! His grandfather Baldev Singh Jandu set up his maiden venture Jandu Engineering Works from humble beginnings in 1972, operating from a 100 square foot rented premises with just one lathe machine that he was operating himself and grew it to become the most prominent supplier of coating and laminating plants in India. His son Gurdev Singh later joined him in business to help his father to further the growth. Their story written by the author in 2013 and also carried by leading print magazine Printweek India,  is already there on the blog https://harveersahni.blogspot.com/2013/01/baldev-singh-jandujandu-coaters-create.html This was at a time when his grandson Prabhjot was still in school. With time, it was felt that there is a need to upgrade equipment in terms of technology and automation, together with expanding the business in terms of size, planning, service and administration. When Prabhjot finished his studies, he joined the enterprise and spent a year or so in training before starting to take decisions, it was like a dose of fresh youthful energy in the company. He is the 3rd generation Jandu to be inducted who is now initiating a complete makeover!

Prabhjot Singh Jandu completed his education with a B.Tech. Mechanical engineering from Amity University followed by business training at the same institution. As a part of that training, he was sent to Adelphi University New York for six months and then to Birkbeck, University of London, England for another six months. On return in 2020, at the young age of 22 years, he joined the family enterprise Jandu Engineering Works and was handed over the responsibility of uplifting the company branding and to take up marketing aggressively. Once he got settled, in order to make component inputs consistent to standard specifications, he moved on to look after purchasing and improving infrastructure to build plants with improved performance of their coating and laminating equipment.

He is now taking it upon himself to create plants that were not only great in terms of aesthetics but also excelled in running at higher speeds with increased automation. Prabhjot endeavors to gradually move away from the basic market that they were catering to and transform his company to cater to the higher end of customers for coating and laminating plants that can make specialty coatings and curing with precision under controlled conditions. He plans to launch coaters for new and innovative products. To make their plants more sustainable they have managed to design and supply equipment that has reduced wastages, with lower manpower and less dependence on operators. For better after sales service, he is introducing remote access so that production downtime of customers is substantially reduced. They now have the capability to access the plant at customer’s premises through internet and diagnose the problem and provide solutions. This has helped them with providing service to their export customers as when they provide internet connectivity, the Jandu service team can troubleshoot and support. They are already implementing real time data access from the plant in production for better and more accurate coatings. Servo drives with software support from Siemens are incorporated for demanding customers. Better tension controls provide uniformity of coatings and smoother run ability. As for providing inline inspection and precision control for silicone coatings starting at 0.30 GSM (gram per square meter) they are ready with the technology but await the right customer who will invest in such a high-end system for their silicone coater. Jandu Engineering Works under Prabhjot’s guidance have started to follow industry 4.0 guidelines.

Earlier, to increase their outreach in the industry, almost all business came to them by reference from existing customers or friends. Prabhjot is making changes and has indulged in extensive marketing and brand promotion. Jandu’s emails are not plain text now and have transformed to well-designed ones and are informative. Their website is up there on the first page when a prospective customer is looking for coaters and laminators. They regularly exhibit at label and packaging exhibitions; in fact, their last international presence was at Labelexpo Europe 2023 in Brussels where it was seen, all three generations manning the booth.

Jandu’s initial growth in the label industry was due to the earliest label printing press that they produced, narrow web CI flexo, but they have now found immense success in building coaters and laminators for the self-adhesive label and other converting industries. Their label printing press manufacturing business is now a very small part of their operations, they are in the process of contemplating either to improve and upgrade their presses or just keep concentrating on coating equipment. There present range has expanded to offer multiple types of converting equipment besides label presses which include coating and laminating machines for; silicone coating and self-adhesive labelstock, specialized coated products, thermal paper, sublimation paper, solar coatings, medical tape coatings, Barrier coatings, PLA coatings, pattern coatings and car wrapping, etc. They also have strong demand for slitting machines as it is necessary equipment for the coating and laminating lines. With experience, Jandu Engineering Works can help new entrants in the coating industry for specialized products with technology, sourcing and other details. They keep acquiring the latest information from suppliers of chemicals and specialized coatings in contact with them who are promoting their technical coatings and advise the processes to be followed. Jandu believes in sharing information with their existing customers.

Prabhjot is happy that the company has grown  60% to 70% since his joining. When he joined their silicone coating line was running at 250 meters per minute and adhesive coating at 100 meters per minute. Now after upgradation the silicone coating runs at 350 meters per minute and after more design changes it is expected to increase to 500 meters per minute and adhesive coating can now run at 180 meters per minute with much improved drying system. Proudly he says, “their earlier customers used to look for basic machines at low prices and now after I explain to them the benefits of the newer technological changes in our equipment, they are ready to invest in the expensive advanced versions of our equipment.” Ninety percent of their customers repeat their orders as proof of their acceptability. Their penetration into the market segment they operate in is more than 80%. While the number of coaters being sold now may be a little less but in terms of value it is much more, almost doubling their turnover because of the sale of advanced equipment to a higher market segment.

Prabhjot is ambitious and with active mentoring and support from his grandfather Baldev Singh Jandu and father Gurdev Singh, he wants to grow the company at a faster pace and endeavors’ a 50% growth in revenue per year. When he joined the company in 2020 Jandu Engineering Works was already operating from a 25000 square feet shopfloor, which has now expanded 60,000 square feet despite the pandemic slowdown. The Jandu family is now looking for about 3 to 4 acres of land for further expansion. The total workforce employed when Prabhjot joined was 70 and has now increased to 120 people. In the last 3 years they have sold around 40 coating lines up to 2-meter width for various applications employing diverse coating methods like air knife coating, 5 roll silicone coating, bar coating, gravure, adhesive coating, etc. These lines have the capability to coat at a speed up to 350 meters per minute. Jandu coaters have been exported to 17 countries so far.

Written by Harveer Sahni Chairman Weldon Celloplast New Delhi January 2024

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Printing magazines may reproduce this article by giving credit to the author.

Labelexpo 2023 reaffirms its significance!

Labelexpo 2023 reaffirms its significance!

Absence makes the heart grow fonder! There was a general perception that the impact of a fierce pandemic, the Finnish Paper Mills strike, Ukraine war, shortages and rising raw material prices, difficult logistics and increased travel costs have left the market sentiments bruised. There was strong narrative doing the rounds in the labels industry that Labelexpo Europe 2023 at Brussels will lose its sheen and may not deliver the desired results. Contrary to all perceptions the show was a huge success. The numbers may have been slightly lower than the previous years, but the quality of turnout brought cheer to the faces of exhibitors. The proof of that is given by the reported rebook rate for the next edition of this important event by Tarsus, announced at a whopping 96%! Labelexpo Europe 2023 was spread over 9 halls covering 35889 square meters. 36588 visitors flocked to the show, coming from 138 countries. Most stands reported robust enquiries or sales from established and serious printers from around the world. Though the aisles were not as crowded as in previous shows, the stands were busy. That is exactly what exhibitors expect from a globally renowned show. I cite a personal experience, I had to conduct an important meeting with one of our company’s several principals. Despite visiting their stand on all days at various times, the concerned person was busy with clients, finally I had to ask him to come to another meeting point other than his stand, so that we could discuss our project in peace. Such was the deliverance of Labelexpo 2023.

The Indian presence; The Indian labels and packaging industry has been continuously growing at steady pace to reach a position of stability and strength. The Indian visitors to labelexpo have also transformed. Earlier we saw many of those who mixed their visit with tourism, so the interest was diluted, and the enquiries lacked seriousness. This trend is seen as changing, given the increased travel costs and technologies evolving in different packaging segments, the smaller printers prefer to visit the domestic editions of Labelexpo. 

In 2005, my company was the only one from India to exhibit at Labelexpo Europe in Brussels, over years the number of Indian exhibitors has been growing. Indian producers of materials, machines and tooling have improved in quality to match global levels and offer their products in the international marketplace. 

From just the one exhibitor from India displaying labelstock in 2005 they reached 14 exhibitors in 2017, and in 2023 the number of Indian exhibitors grew to 26. This number included several label press manufacturers, manufacturers of coaters and laminators, raw material suppliers, tooling manufacturers, etc. In fact, registering their presence in all segments of label manufacturing. As for the visitors, it is an even more interesting result. In 2019 2% of the total of 37903 visitors were from India.

This works out to over 750 visitors. This figure has swelled! In Labelexpo Europe 2023. Indian visitors were 3.9% of the total of 36588 visitors and this works out to over 1400 visitors, almost double the number. We can imagine the dynamism and steady growth of “make in India” concept. The Indians are now quick learners who visit these shows and become adapters of global technologies to produce and offer to the world.

Diverse technologies displayed: Labelexpo global series was in the initial stages aimed at growth of stickers that had evolved as self-adhesive labels. The earliest web label presses were largely coming from eastern part of the World as 4 or 5-inch-wide flatbed letterpress machines for printing labels in roll form to eventually transform with development of label applicators, it led to automation in packaging lines.

Development and introduction of rotary flexographic label presses brought a paradigm shift as it provided better speed of printing.

Since the web width in the earliest stages was small, the industry eventually started being referred to as narrow web label industry. The rest is history. With evolution and development of prepress printing speeds and quality also improved making the technology widely acceptable. Printing widths increased to 10 inches or 250 mm and had for quite some time settled at 330mm.

Speeds that were just 5 or 6 meters per minute in the beginning with the flatbed presses, have reached up to 200 meters per minute and more. The narrow web label industry flourished and kept growing. With time label technologies have undergone a sea change. What was wet glue labels, transformed into self-adhesive labels but later the label grew towards various tangents. The label users started adopting a wide variety that includes wraparound labels, shrink sleeves, Inmold labels, heat transfer labels and many more. In the initial stages of transformation large multinational FMCG companies became users of wrap-around labels and shrink sleeves, because of the large volume they required, these became the product of the wide web rotogravure printing industry. With market changes happening, the need of smaller manufacturers and demand for short runs by marketing professionals, these diverse segments also became evident in the offerings of narrow web industry. 

The narrow started growing wider still, printing and converting evolved exponentially and became suppliers of not only to wide spectrum of labels but also flexible packaging, Lami-tubes and folding cartons. The flexo presses also transformed to be hybrid ones  employing combination of flexo, offset, gravure, screen and digital, etc.

At Labelexpo Europe 2023, one could witness displayed, a merger and combination of different printing technologies to produce excellence in print of labels and packaging. This was substantially exhibited by industry stalwarts like Gallus, Omet, Nilpeter, Mark Andy, Bobst, Weigang, Lombardy, etc. who displayed their finest web printing and converting equipment. It is interesting that waste reduction and sustainable manufacturing practices to reduce carbon footprint are becoming imperative for all responsible machine builders.

Overview: Material suppliers like Avery Dennison, UPM Raflatac and Fedrigoni displayed their vast ranges of labelstocks with an evident effort towards sustainability. Many did talk of linerless and the initial developments they have made but the actual linerless self-adhesive label for mass usage is still a far cry. 

As mentioned before, from the just one Indian Labelstock producer in 2005, there were five Indian labelstock producers at the show, Jindal SMI, SticOn papers, MLJ, Shree Lamipack and Varshil. Looking at the number of visitors on stands it was clear that the focus of label fraternity is shifting from commodities to creativity, innovation and sustainability. While all labelstock companies had a steady flow of visitors, the Fedrigoni stand that offered specialty textured and decorative materials was extremely busy. 

A similar situation was observed at the Cartes stand whose displayed equipment offered amazing embellishments with various combinations of digital jet screen varnishing and printing, screen printing, laser die-cutting etc. The electronic integration in labels is another field that attracted the attention of forward-thinking printing companies. RFID insertion options for labels and packaging were displayed by many, some of whom include  Avery Dennison, Beontag, Muhlbauer, Delta Modtech, etc. Another aspect witnessed is the growing number of finishing equipment manufacturers, which clearly indicates the need for printing companies to produce more with less. The concept of printing at full machine speeds on their expensive presses and finishing offline makes available more time on their main printing presses. The futuristic digital printing equipment continues to evolve indicating it to become a dominant label printing technology in future, given the wider widths and faster speeds.

The hall number 8 with exhibitors led by HP, offered a vast variety of digital printing equipment. The increased display of finishing or digital finishing machines is also indicative of the increasing importance of digital printing, which in recent times has become a necessity for prosperous label printers. Running short runs needs offline finishing. else the digital presses with inline finishing will not only be expensive but will not be able to deliver production to their full capacity due to short runs and quick changeovers.

One thing that has become evident at Labelexpo Europe 2023 is that the narrow web label industry continues to go wider and evolve, increasing its footprints in other segments of packaging and it would not be out of place to mention that soon it  will be referred to as “Web label and package converting industry.”

The end of show was a nostalgic moment, people bidding farewell to Labelexpo in Brussel where so many wonderful memories, stories of success and friendships had been scripted. The label fraternity now looks forward to making another beginning with Labelexpo Europe 2025 in Barcelona, Spain.

Pictures of my walk through Labelexpo 2023 and some of the events on the sidelines;

World Label Awards Judging:

One day before Labelexpo opened, the judging for label awards was held.

Same afternoon, L9 meeting was held, followed by L9-Dinner

The global Label awards evening!

On Wednesday 13th September 2023, fairwell dinner for Label Guru Mike Fairley was held

My Walk through!

Written by Harveer Sahni, Chairman Weldon Celloplast Limited New Delhi India September 2023

Pamex 2023 justifies theme; “Convergence of print.”

Pamex 2023 justifies theme; “Convergence of print.”

Ever since 1450 when goldsmith Johannes Gutenberg invented the movable-type printing press, which started the Printing Revolution, printing technology has been evolving. The technology has come a long way from the first use of flat wooden blocks being inked and stamped on to paper to production of metal typesetting mechanizing the process. The history is very interesting and long. Printing process or technology has evolved in many forms of contact printing from flat bed to offset printing in sheet and roll to other forms of printing like rotogravure and  screen to finally reach the present-day non-contact digital printing without the need of blocks or plates and with just click of button from computer to print.

With time, labels and packaging evolved and there was a dire need to decorate the packages and labels to catch the attention of discerning customers. Embellishing processes have also been developed to become an inherent part of printing and converting process. These include varnishing, hot-foiling, cold-foiling, embossing, debossing, lamination, die-cutting etc. With the development of different printing technologies it became apparent that each technology has its own advantage. For high quality images to reproduce skin tones and vignettes, offset is preferred. For the desired pantone shades, flexo is preferred.

To achieve higher deposition of ink, screen printing delivers the desired results and to get the good metallic effects in printing with metallic inks, gravure printing is used. To produce personalization in print, have variable printing, to achieve track and trace information and security information, digital provides the option. The advent of organized retail and e-commerce becoming a part of our daily life, has brought about the need to bring the best of each technology together and achieve excellence in printing and packaging. The organisers of Pamex 2023 exhibition, All India Federation of Master Printers (AIFMP), in association with Print-Packaging.com saw immense value in adopting the theme “Convergence in Print” and delivering the importance of this theme to printers and other visitors to this prime show.

The theme was conveyed to the printers in the nation at different geographical venues in India  by the promoters. Roadshows with presentations by sponsors offering equipment with convergence in print and panel discussions were a part of these presentations. Technical presentations on technologies such as printed electronics were also a part of the roadshows. Diverse information and knowledge was delivered to attendees at locations like Bangalore, Pune, Guwahati, Indore and Haridwar.

The focused efforts by the team of AIFMP headed by President Ravi Joshi, Tushar Dhote and organizer Anil Arora of Print-Packaging.com produced a successful event. The final show Pamex 2023 held at Bombay Exhibition Centre Goregaon Mumbai on 27th-30th March 2023 was an immense success. 33,812 visitors and over 450 exhibitors thronged the venue and came from many countries around the world.

On the penultimate evening Pamex 2023 played host to a glittering awards ceremony at the Gala Exhibitors’ Evening. AIFMP decided to institute several new awards to add to the prestigious NAEP and  VCPLA Awards that were given away in the last edition. The awards was with full attendance and printers and suppliers networked and celebrated the togetherness.

I present my walk-through pictures of the event:

Driving profitability in labels!

Driving profitability in labels!

 Driving profitability in labels, with embellishments, digital printing & hybrid printing

Self-adhesive or pressure sensitive labels industry in India has grown steadily right from the time of its initial entry into India to be indigenously produced in the mid-1960s when a screen printer manually created the first label. Thereafter, label manufacturing has evolved and completely transformed  technically over the years. Initially, small and slow very narrow web letter presses, 4 or 5inch wide, from the eastern part of the world were used to print with blocks and die-cut labels with flatbed dies in roll form. These presses eventually started going wider in printing width with growth in demand. The need for increased production in 1980s brought in the adoption of rotary flexographic printing presses. However, since the flexo plate technology was just evolving, usage of letterpress block printing was still growing. It was in the new millennium that developments brought in prepress and plate making technologies, made it possible for printers to decrease their dependence on letterpress printing technology and invest in flexo presses that eventually became modular and print widths going wider with increased speeds.

Toward the middle of the first decade of the new millennium, the pop and Mom retail stores, known as Kirana stores catering to consumers, started being replaced by the entry of organized retail outlets and with it, came the increase in demand for labels and packaging. When it was realized the customer’s point of purchase decision to lift the product off the shelf is the driver for sales, brands felt the imperative need for attractive labels and packaging. Different print technologies started being employed and presses with advanced capabilities started being developed and offered. While all this transformation was happening, the label industry in India was all along registering a robust double-digit growth. It was largely accepted fact that even though labels are a very small part of the large packaging industry, it was more profitable. Due to this, the number of label printers kept growing, investments also came in from established offset printing companies. With cheaper label presses coming from China and availability of good affordable machines in India, the label printing capacities have grown exponentially. This increase in capacities, the pandemic, the strikes in Finnish paper mills, the Ukraine war, the re-emergence of Covid in China,  etc. brought the margins in the labels industry under intense  pressure. Raw material prices have since escalated, freight rates, salaries and overheads have increase while competition does not leave room for increase in selling prices. In such a difficult scenario, label converters are looking at options to drive in profitability.

Opinion and comments of label printers across India was sought on how to drive-in better margins in the label production in the given circumstances. Three questions were posed to all, their response is somewhat similar, yet some do have apprehensions about the steps that are suggested whether they will actually drive in margins? However still, a direction on the way forward appears to be an imperative. The  printers in the diverse geographical zones who contributed their views are as follows;

North:

Anuj Bhargava, Kumar Labels NOIDA hereinafter referred to as (AB)

Rajeev Chhatwal, Kwality Offset New Delhi (RC)

West:

Mahendra Shah, Renault Paper, Palghar (MS)

Himanshu Kapur, J K Fine Prints Mumbai (HK)

Priyank Vasa, Unick fix-a-form, Ahmedabad (PV)

East:

Manoj Kochhar, Holoflex Kolkata (MK)

South:Raveendran Selvarajan, Seljegat Sivakasi (RS)

Lakshminarayanan Parthasarthy, Signode India Ltd. (Wintek) Bangalore (LP)

Question: Do you agree that Embellishments, Digital printing & Hybrid printing or converting are important steps to get better prices for labels?

AB: Yes, value added labels do add to margins. However still, the main buyers are few. Startups or premium products cannot add volumes where multiple players offer value additions. 

RC: Embellishments certainly will get you a better price if you have a technical edge over your competition. Just a  different printing process does not get you more price from customers. One needs to decide which process to use to get better return based on machine capabilities .

Hybrid is still not suited for the Indian Market. However good converting and finishing is important for short runs on digital to reduce wastage.

MS: Yes, I agree. With increase of just-in-time orders, shorter runs and demand for innovations,  it is economical and faster to produce with Digital printing. Embellishments complemented with other capabilities, aid improvement in value addition.

HK: More technical the labels are, better is the margin. Unfortunately, large companies expect more for less. The basics of costing has been lost by most label converters. Embellishments also add to costs, but to recover those costs is difficult.

PV: We aim for the best process fit for a job, be it digital, flexo, hybrid or offset. That is the only way to master production cost. Digital embellishment always gives an edge and keeps business secure but does not always guarantee increased profitability, it comes with its own limitations. 

MK: I agree that Embellishments, Digital printing & Hybrid printing or converting are important steps to get better prices for labels. Value addition invariably leads to a better realization. Brand protection elements such as hologram, security inks, security designing also add value.

RS: Not only embellishments, but also innovations along with having capabilities for attending to needs of customers are important. If food and pharma customer needs labels with water-based inks, we need to have those capabilities. If they need booklet labels it becomes an imperative to be able to create them. Every printing process has its own specialty so when you are able to create labels with Hybrid and digital technologies, then of course selling prices are better.

LP: QR codes and AR (Augmented Reality) in labels, connecting consumer to the brand – is what we see as way forward for profitability . Embellishment leads to aesthetics, shelf appeal, increased sale and brand value for better profits to the buyers and converters.

Question: Have you taken any steps in this direction to increase your capabilities?

AB: We are always focused to value added labels. We have capabilities do embellishments like 3-D effects, embossing, textured foiling, screen printing and many other such processes that enhance the aesthetics of product.

RC: We have already invested in converting equipment with finishing and embellishing capabilities like foiling, Screen printing, Lamination etc. Our range of labels includes- Foil stamped/embossed labels, labels with tactile effects, Laminated, 3-D embossed, Variable data and Holographic labels etc.

MS: Since long, our customer profile is such that embellishments and employment of multiple print technologies is an imperative, for this reason we invested in hybrid presses many years back. Currently to achieve just in time capabilities we are investing in digital printing which will also give us additional production time on our main printing presses.

HK: We have always invested to be a capable company, right from inception so have the capacity to do all types of embellishments.

PV: Yes, we have added digital capabilities. Having multiple printing technologies at our disposal, enables us to pick and choose processes that are best suited for a particular job depending on the complexity of decoration required. 

MK: We are constantly trying to scale up our capabilities of adding diverse authentication features and other embellishments such as foiling, registered hologram stamping, variable data printing and finding new materials that are unique.

RS: At Seljegat we always endeavour to stay invested and capable with the latest developments. We have already installed machines with multiple capabilities, and we prefer all inline. We can do embellishments, special varnishes, multilayer labels, digital for variable or personalized labels, embossing, etc. We are always ready to cater to the changing needs of customers, nowadays pharma and food companies are demanding labels to be done with water-based inks or low migration inks, we have immediately empowered ourself suitably to serve them. In today’s time if we cannot deliver that extra, then we get lost in the crowd of intense competition.

LP: We are already having all capabilities and exploring AR in labels as next step towards Brand connect and Brand promotion. 

Question: What in your opinion are factors that can drive in better margins? Please mention steps at given prices of inputs.

AB: Label companies should invest in making labelstocks for captive use, negotiate hard while buying machines and for buying raw materials.

RC: As competition gets aggressive, systems need to be designed to reduce wastages, increase productivity and buy raw material at competitive prices. Making our internal systems strong is the only way out to drive-in better margins.

MS: We started the process of optimizing production costs, long time back. We collected data of all ongoing jobs for past 3 years and calibrated all processes as per the following;

a) We dwell on actual time needed for the job and check if the processes are complying with targeted numbers.

b) If not complying what’s the core reason and if for some reasons not meeting norms,  can solutions be found?

c) Evaluating, if no solution is possible, is the job generating profit for the company? 

d) If not , either get the price increase or discard such jobs to save time for more sustainable jobs.

HK: Rather than controlling the input prices on which we have no control, we should focus on getting better prices from clients. We need to factor-in the basics like label waste that is completely non-recyclable and cannot be salvaged. Label machines are capital intensive we must add the impact of cost of investment in the total price of end product.

PV: To improve profitability;

Freight cost management is an imperative, it can save lot of money.

Process improvements and wastage control is necessary. One should start with small steps like exact web sizes, proper sheet layout, special sizes for volume jobs, ink management and keeping a track of low moving stocks.

Refrain from unhealthy competition.

Learn from your mistakes as a team. Take all complaints seriously. Try implementing simple solutions. 

Update monthly  performance chart of individual operators,  give them incentives for faster turnaround and increased capacity utilization. Take corrective steps to reduce downtime due breakdowns. 

·      MK: Key to improve margins is to provide customised solutions by understanding what the customer needs. We try to incorporate various levels of authentication, embellishments and decoration to tailor solutions that best meet their needs. If a customer cannot afford to pay for the hologram, we focus on enhancing the printed authentication features keeping costs under control, and yet get a price that enhances our profitability while the customer appreciates the value we deliver.

RS:  For driving in better margins, the instant reaction is to buy cheaper but if we have to think of steps at given raw material prices then one has to research internally and implement changes. As a first step we have opted for equipment and steps for faster changeover time between jobs to increase productivity. We have invested in a system for make ready to be completed before one job ends. The changeover time for us has reduced from one and half hour to just thirty minutes. For job set up we were using fresh labelstock but now we use rejected, old and leftover unusable stocks. Next, we are now switching over to LED UV as its operational and lamp replacement cost is lower. New equipment has been ordered and will be installed soon. We plan to install an automatic butt slicer for non-stop production. Reducing wastages is also on our radar and we constantly work on it.

LP: The following steps are necessary to drive in profits;

Watertight operations, control on wastages and minimising set-up waste.

Reducing overhead costs, improving efficiency and OEE (Overall equipment effectiveness).

Propose embellishments to customer making the label more premium to claim better realisation.

Summation:

Price increase is an ongoing process, the impact of inflation is felt every year along with that of other unavoidable circumstances. So, manufacturers need to gradually increase selling prices to maintain a healthy bottom line. Unfortunately, that is an ideal scenario but in actual the selling prices are driven by market dynamics and competition. In the present situation, for the label industry, it is time to look internally and evaluate. Based on the views of the printing fraternity it is largely agreed that embellishments, security features and innovative concepts on labels that enhance the shelf appeal and lead to better sales volumes for brands, can help get better prices. The simpler the label is, more is the competition. As indigenously produced label presses have come within the reach of middle level printers, the competition in that segment has become intense. Moreover, with organized retail and ecommerce becoming the predominant selling systems, need for more decorative labels, IT enabled labels and personalized variably printed labels  with security features has escalated.

Not long-ago setup of label jobs took an hour or more with 2 or 3 persons on each press and at least 100 meters of material being used before final saleable production commenced. With increased automation, advanced automatic registration controls, higher speeds, etc. now a single operator can setup a job in just a few meters in about 15-30 minutes, with increased productivity, less wastages and quick changeovers between jobs by keeping the next jobs ready. Using exact size materials and not generating offcuts is also a necessity. These are changes that add to margins and reduced operational expenses.

Food and pharma safety and health concerns are matters of importance for discerning customers, this, along with statutory rules for toxic or unsafe materials used in converting labels, are to be avoided. There is an increased demand for non-migration and water-based inks because UV inks are considered somewhat hazardous for direct food contact and skin contact applications. Printers need to have such capabilities to supply as demanded by print buyers. Most companies feel that to reduce costs there is need for internal production systems and the workflow to be strengthened or monitored continuously to reduce downtimes at each stage, opt for more automation to reduce manpower and use energy efficient machines, equipment or systems.

Finally, time has come when EPR (Extended producer responsibility) compliance has become mandatory. Sustainability and circular economy are becoming a social responsibility for earth to be a safer planet. Large FMCG companies and brands have already started opting for or expressing preference to buy from certified green companies. It will not be out of place that producing in compliance, may as well add to cost but it may also qualify for better pricing for this good social cause.

Written by Harveer Sahni Chairman, Weldon Celloplast Limited, New Delhi February 2023

LMAI Webinar: Label printers’ woes, price increases and shortage of inputs

LMAI Webinar: Label printers’ woes, price increases and shortage of inputs
Frequent increase in paper prices have been adversely impacting the printing and packaging industry in recent times. The print industry has been at the receiving end not just because of the price rise but also due to shortages of paper and that too at a time when demand is rising. The printers have suffered because of long lockdowns due to Covid-19 pandemic; they had hardly heaved a sigh of relief as the situation started to improve when prices began their upward movement followed by shortages or unavailability of critical inputs, adding to their operational problems. The self-adhesive label printing and converting industry is an extension of the sheetfed or unsupported web printing industry. Unfortunately, the impact of the present situation on label printers is more severe, given the complex nature of their major raw materials, the self-adhesive or pressure sensitive adhesive labelstock. Unlike the single layer substrate that paper or board is, the labelstock is a laminate with many inputs. The face materials vary from various kinds of paper substrates, films, foils, etc., then there is a range of pressure sensitive adhesives like emulsion and hotmelts in variants like permanent, removable, for low and high temperature applications that are formulated with various polymers, plasticizers, emulsifiers, and other chemicals. Lastly the release base papers and silicone formulations. All these inputs are facing price increases. Realizing the impact and seriousness of the situation, LMAI (The Label Manufacturers Association of India) initiated by the current President Rajesh Nema, organized a webinar titled "Knowledge – Accelerating Growth" on 30th October 2021. The panelists included Saurabh Agarwal-Avery Dennison, Ajay Mehta- SMI Coated Products, Prashanth Raveendran- Seljegat Printers and Manish Desai- Mudrika labels. The webinar was moderated by Jaideep Singh Secretary LMAI and coordinated by Anurag Mohan Management committee member.

 

 

 

Ajay Mehta
Ajay Mehta spoke on the gravity of the situation due to rise in prices with price increases being announced by paper mills frequently despite not getting their full requirements of materials. Forward contracts are made with paper mills but those are for quantities required and mills in general, charge prices prevailing at the time of dispatch. However still, the increasing international freight rates, reduced availability of raw stocks with mills and the upswing in demand impacts adversely. While the mills give a date whereafter new enhanced prices will be applicable, but the adhesive suppliers do not even give time for price increase and announce the new price with immediate effect. Paper mills supplying release base papers are either facing shortages of pulp so have lesser materials to offer or they to recover the losses incurred during lockdowns are directing their materials to markets where the get higher value for their products. He cautioned that by modest estimates, the label industry will stand to lose over Rupees 250 Crores annually and there is no way this loss can be absorbed, they have no alternative but to pass on the price increase to the printers. They do get resistance from some quarters but there is no way to compromise on this if one has to survive and keep the company in sound health.

 

 

Manish Desai

Manish Desai of Mudrika Labels mentioned that print buyers strongly resist the price increases by expressing that there are other printers ready to supply at lower rates, however according to him they must be persistent as there is no other option. The possibility to downscale the product specification by lowering substrate grammages and adhesive coat weights to keep the prices stagnant is not the right step and will lead to inferior quality and rejections at the customer’s quality control. Moreover, since many print buyers are now mentioning the standard brand labelstock usage in labels supplied to them, printers do  not have the option to consider alternate suppliers. He suggested to the labelstock manufacturers that since they interact with print buyers to get their materials approved, they should in turn also impress upon to approve price increases in tune with raw material price escalations. It would also be prudent for labelstock manufacturers to make forward contracts with raw material suppliers such that they in turn can give some breathing time for printers to settle down with new prices. Price rise is an ongoing process in growing economies and eventually the industry settles down with it in 3-4 months, unfortunately now it is at a challenging time and too frequent. He further added that amongst their customers, with privately owned companies it is easy to get price approvals as one can deal directly with senior management and justify the need for higher prices. Contrary to this, it takes 3 to 6 months to get approval from multinational companies as they have multiple layers of management and the price approval is a long-drawn process and by the time the approval comes, the prices may already have increased some more.

 

 

Saurabh Agarwal
 

 

 

Saurabh Agarwal of Avery Dennison mentioned “'The significant increase in demand post the improvement in pandemic impact, especially in the large economies of the world, while the supply environment continuing to remain constrained has been the single biggest reason for the serious inflationary pressures. The rising oil and energy prices and the prevailing ocean freight crisis intensifies the impact and is now impacting almost every region. At Avery Dennison, all our efforts are geared to continue serving our customers in the best possible way during these volatile times, while at the same time keeping them informed of the prevailing situation.”

 

 

Prashanth Raveendran of Seljegat Printers was more focused stating that they have reached a level of success by continuously investing in the finest equipment to manufacture labels to international standards and creating innovative products. He said, not getting the appropriate and remunerative price for their products will hamper their growth and not justify their huge investments. He stressed that if some print buyers do not understand the situation and do not agree to give the right prices, unfortunately and sadly we will have to forego such orders. After all, we have to service our financial commitments.

 

Priyank Vasa
To get a wider view on the topic the author interacted with some more industry constituents. Priyank Vasa of Ahmedabad based Unick Fix-a-Form says, “The recent price hikes and inflation in raw materials has got us wondering how long we can sustain a healthy margin while continuing to offer the best rates and quality to our customers. Production efficiency has been impacted in the past two years because of the pandemic. Looking at the current situation, it is tough to offset increasing cost of raw materials with an improved efficiency. Labels have become a commodity, unlike older days where one could reap the benefits of developing a product for years altogether. Product  diversification could be the key which could offer a good balance between profitability and volume. Current market conditions do not offer many niche segments where business could thrive. Sustainability of the margins will take the driving seat vs the volumes. Expansion models must be feather light as nature of our industry needs repetitive investments that come with an interest burden.”

 

 

Mahendra Shah
Mahendra Shah of Renault Paper Palghar, a part of Manohar Packaging group says, “We call ourselves manufacturers of labels but technically, we are just converters without any consumer brand-value which can be encashed at a later part of our entrepreneurial tenure. Our current or past investments do not last long, due to fast changing technology. If you do not capitalize your investment in the first one thousand days, your time and energy is wasted in just recouping the investments done. Really, is this why we became entrepreneurs? Competition was always there and will remain in future, the only difference is the mindset. Now with fast evolving technologies we need to achieve the  return on our investment at a faster pace. As first-generation entrepreneurs, we took harsh calls and succeeded, with this huge price impact on our inputs now, we all need a fearless attitude to go for price increases from our customers before it is too late. We may lose some customers but with clear thoughts I am sure we can all make our business profitable and sustainable.” 

 

 

Anuj Bhargava

 

 

Anuj Bhargava of Kumar labels asserts that the price increase must be passed on and it is an imperative for survival. Another point he mentioned is that the industry is not realizing that people are a necessity in a company to work efficiently and the cost of people has dramatically increased post covid. So that cost combined with the enhanced raw material costs is a “Killer.” If label printers do not pass on the impact of the combined cost increase, then definitely it is a formula for suicide.

 

 

The PSA or self-adhesive labels industry is already at crossroads whereby evolution is leading to a lot of demand growth going off to different evolving technologies like shrink sleeves, inmold labels, wraparound labels and direct on product digital printing. Expansion in capacities coupled with commercial and other offset printers, facing pressure from the online communication, also investing in label manufacturing is bringing about intense competition and pressure on profit margins. Label manufacturing also has another challenge which is becoming a matter of concern and that is the waste management. Adhesive coated waste matrix and the release liner that form more than 50% of the laminate is either going to landfills or being incinerated. Facing pollution controls and attending to environmental concerns the printers must now invest in measures that support sustainable and environmentally safe production processes. At such a time when input prices are going up putting margins under pressure, their woes keep on escalating, prompting them to get together as an industry and ponder over workable solutions to counter the concerns that are arising. The positive side is that in a large country India with a huge young population, the growth is evident and there will be enough for all label manufacturing technologies.

Written by Harveer Sahni Chairman Weldon Celloplast Limited New Delhi November 2021

 

Printweek India's edited version of this article  is also available at; https://www.printweek.in/Features/label-printers%E2%80%99-woes,-price-increases-and-shortage-of-inputs-55396 

Abhay Datta, a printer’s tryst with machine building

Abhay Datta, a printer’s tryst with machine building

On any given day, 96-year-old S.N. Dutta, Satya Narayan Dutta, the patriarch of Dutta family of Dutta Press New Delhi, can be seen strolling on the shop floors of their printing or machine building units, interacting with workers, and imparting instructions. The man is active and an institution himself in printing. Dutta was born on 15th of August 1926, long years before the partition of India, in a family that hailed from Lahore, then a part of British ruled united India. His father was the head of accounts for Indian railways. Sometime in the 1940s as a young man, he developed an interest in printing so went to a family acquaintance, Kedar Nath Mehta, a master printer in Amritsar for a one-year training in the art of printing. They used to print on Chandler & Price platen presses and supply labels to Punjab based distilleries in Hamira and Khasa. Chandler & Price was founded in 1881 in Cleveland, Ohio and manufactured a series of hand-fed platen jobbing presses, as well as an automatic feeder for these presses.

 

Chandker and Price Machine
Love marriages were rare in those days before the partition of India, however S.N. Dutta during his training days at Kedar Nath Mehta’s facility, developed a liking for Mehta’s daughter and eventually married her. Post partition the Dutta’s moved to their Haveli, a traditional townhouse mansion in Darya Ganj Delhi. The Haveli was a heritage building that had earlier belonged to one Sir Syed Ahmed Khan, one of the Navratans of Mughal King Akbar. It was allotted to Duttas on migration from Lahore to Delhi after partition for a sum of Rupees 4000 only. In 1951 S.N. Dutta started his maiden startup venture “Dutta Press” with a Chandler and Price machine on the ground floor of their Haveli. He bought the printing press for Rupees 1200.00 and did not have the money to put an electric motor on it. So, initially the machine was foot operated with a peddle. As a memento and a reminder of their past, the machine still stands tall on a pedestal in the lobby of their Okhla factory. Thereafter from 1951-1965 Dutta was on the move continuously, he also set up his own typesetting and composing section, then added two more machines, following it up with buying a new Heidelberg GT Platen press for just four thousand Rupees, then in the mid 1970’s a Mercedes Super Cylinder Press from Printer’s House in Faridabad, Nibolo and some more letterpress cylinder machines. Customer base acquired during this period included those from segments like beer, whiskey and lubricants with main customer being Mohan Meakin. S N Dutta has two sons Rakesh and Abhay, as business had grown and the boys were now grown up, it was time to move to the next level of business. In 1980 they moved to a new factory in Okhla and imported their first Heidelberg KORD offset press and Heidelberg TP Foil stamping machine from Germany. Those were tough times of needing import license for all imports, yet firm resolve made them to move on.

 

 

Heidelberg Weisloch Factory
Abhay Datta the younger son of S.N. Dutta, born on 16th August 1961, is an Alumnus of St. Xaviers School Delhi. He was never a serious student but had other technical interests. Barely 16 years old and in school, he started experimenting with making music systems. On finishing school, he along with his friend Joseph George set up their maiden startup venture Systm India to make and sell music systems. Abhay proudly mentions that in a couple of years his company’s turnover was higher than that of Dutta Press. Young boys in business families are prompted to spend time in family production units and Abhay was no exception and whatever exposure he got was by way of his father mentoring him to have a penchant for perfection and zero tolerance in whatever he did. One fine day his father came to him and complained, “you make so much noise testing your music systems, speakers etc., neighbours are irritated . It is not a respectable business. He appealed to Abhay that they needed help in the printing business and that he should wind up this music equipment business and join him in the printing business. Obedient as he was with immense respect for his father, Abhay could not refuse his father’s request. Abhay’s elder brother Rakesh was better in finance and other marketing activities. In just a matter of minutes Abhay decided to hand over the music business to his friend Joseph and moved on to the printing business at Dutta Press. He was sent to Heidelberg training center in Germany for training in print technologies where he spent time in the Wiesloch factory understanding mechanics and engineering of offset presses. It was an eye-opening experience for him. In India we did not have CNC machines, no auto cad computers, all the planning was done manually on huge drafting boards. It was there in Germany that he gathered an eye for perfection, low tolerances, fine finishing, good appearance and machine safety norms. This was as his father had mentored him to be a zero-tolerance person.

 

 

UV Coating Machine
Once back in the Okhla factory Abhay had to begin at the lowest rung of the ladder. He was required to clean up the machines, sweep the floor, take care of staff, serve them tea and support them in small errands besides operating all the machines personally. He learnt to run all the machines like an operator, make negatives/positives and offset plates and foil stamping blocks himself. Those were days when there were no PS plates, so he learnt all the chemistries hands on. Graining offset plates, putting sand, marbles etc. in graining machines, he did all that himself. He was a total worker like any laborer in the factory doing all kinds of jobs that included printing varnishing cutting packing and dispatch. The experience has rubbed on so well on him that even today on the shop floor in hot and humid conditions with perspiration trickling down his torso he enjoys remaining amongst his workforces. He is a hardcore technical and shopfloor production-oriented person while brother Rakesh manages the white-collar part of management. With Abhay’s penchant for perfection, he proudly mentions that we made quality, such that print buyers would come looking for them. Since they were supplying to breweries and distilleries, they came across a challenge; solvent base varnishes on labels scuffed and needed to be replaced with Water based varnishes, but these would not work on existing hand fed varnishing machines produced locally due to slow drying. Abhay was given a task by his father to make a machine that could coat aqueous varnishes at high speeds. He developed an automatic machine with the help of Sanjay Gupta of Ronald Machinery and added an anilox roll with a motor and hot air dryer to do the varnish. It worked and that was when his tryst with machine building commenced. Later he started manufacturing fully automated high-speed machines to do aqueous and UV coating with anilox rollers and chamber doctor blade systems.

 

 

Abhay Datta on Shop Floor
 

 

After that there was no looking back in machine developments. Abhay was young, success encouraged him to research, experiment and develop more from a shed in the driveway of their Okhla factory, it has been a long journey with lot of hurdles. He then started converting hot stamping machine for own use and sales. Since in earlier days they had bought a Heidelberg hot stamping machine, from experience gained, Abhay could convert die cutting machines and the Chandler and Price machines into hot stamping machines. When stamping foil suppliers became aware of his capabilities to make hot stamping machines, he became an accredited suppliers to many companies who indulged in hot stamping. In 1992 he successfully started making UV coaters and till 2016 they have supplied over 250 offline UV coating machines in India and Abroad.

 

 

During his 1995 visit to Drupa, he was fascinated by an Aquaflex label press printing Smirnoff Vodka labels. Unlike the sheet fed converting, the press was unwinding, printing, embellishing, laminating, die-cutting and delivering finished labels at the end of line in a single pass. Abhay was convinced that this is the future. Those days there was no WhatsApp where he could take videos and upload to inform his family about the equipment. Wanting his father and brother to also look at the machine before deciding, he made a trunk call, described the machine and requested them to come and see. Three days later both his father and brother flew into Germany, they saw and fell in love with the machine. They became friends with the founder of Aquaflex, signed the deal to buy a press and also became the sole selling agents in India. They opted for an eight colour press with rotary hot foil stamping. It was a bold decision as rotary tooling for hot foiling was very expensive, cold foil was not there that time and most of their production for liquor labels needed foiling. In their factory they already had 20 Heidelberg hot foil machines running, they used to buy used Heidelberg platen machines and convert them into hot foil stamping machines by retrofitting, all done by Abhay himself. The Aquaflex ordered by them was displayed at Labelexpo Singapore in 1996 and then shipped to India for Dutta Press to start printing labels on a narrow web press. Till the end of the millennium 1999 they were only printing wet glue labels on this machine. Pressure sensitive adhesive (PSA) labels production commenced only in the new millennium in 2000, they kept adding Aquaflex presses in regularity.

 

 

Ultraflex Label Press
Between 1996 and 2003 as agents, they sold nine machines to customers like PPL, ITC, Modi Federal, Sai Packaging and others. They added four more press at Dutta Press. In 2001 Aqua flex got sold to Chromos USA . At this time when he was under pressure to offer a press to his customers, he met a software engineer who suggested the name of Shanti Pal Ahuja of Multitec and once the two met, they instantly decided to get together to build label presses. Abhay invited Ahuja to his facility and have a look at the Aquaflex label presses and to do reverse engineering of the press. A complete unit was removed from the Aquaflex and sent to Multitec facility in Faridabad. It was completely meticulously redrawn and the first Ultraflex machine was developed and sold to Nishi Labels in Ahmedabad and the second machine was exhibited at Nehru Centre in the first “India Labels show” which later became Labelexpo India. That machine got sold on the very first day of the show to Khosro Moradi, of Farah Banfash Manufacturing Company, Iran. Few years down, having sold over a dozen presses, their partnership fell apart and Multitec renamed their press as Ecoflex and Abhay Datta retained the name Ultraflex that he would build himself one day. Until such time for their own label manufacturing they invested in Bobst label presses

 

 

CNC Machines at UV Graphics
Passionate about making machinery himself, in 2017 after they bought their 3rd Bobst M5 press, Abhay visited Florence and was inspired to build his own flexo press. On return from Florence in September 2017, he dug deep into the Flexo Machines and studied other equipment that would enable him to build a narrow web label press. Keeping cost down and not compromising in automation he started planning a machine with zero waste and instant make ready. He launched his first Ultra flex made in his company UV Graphics. 

 

 

 

 

Ultraflex Plate Mounter
He insists that for a perfect and quick make ready, “a communication between the plate mounter and the machine is imperative.” Abhay also started making plate mounters. He asserts that with plates mounted on his plate mounters, the first meter of print which rolls out will be 99% in true register. This is his creativity. His machines and plate mounters are designed as perfectly complementary and compatible equipment  so as to make life easy for the machine operator. He claims that in 3-4 minutes you can perfectly mount an eight colour job on his plate mounter and have the machine running in full register within 3-5 meters. That says Abhay is our USP. Ultraflex machines offered by him are of international quality, fully servo driven with auto register control, it is value for money and affordable. Ever since, Abhay has already installed thirty-eight presses in India and abroad with the latest ten color machine being shipped to a prestigious customer in USA. This will be his first installation in North America and fifth machine being sold overseas.

 

 

 

Abhay has two sons Anuj and Akshay and a daughter Aallia. Both sons run the PSA labels division of Dutta Press while brother Rakesh manages the wet glue label business from Okhla. All family members are in business together as a joint family. UV Graphics and Dutta Press operate out of 66000 square feet factory in Noida and an 18000 square feet facility in Okhla with seven flexo presses in Okhla and six flexo presses in Noida. With a total of 280 employees, Abhay aspires that if God and Kismet helps UV Graphic will be a leading global supplier of diverse label equipment in 5 years. He proudly says, “we produce from nail to the hammer. In UV graphics we produce our own UV Systems, Plate mounters, Core cutting machines, Label presses, Slitter Rewinders, Semi Rotary Digital Finishing, Print Cylinders, Magnet Cylinder, Sheeting Cylinders, Hot Foiling Stamping Equipment, Screen Printing and almost everything that is needed for flexographic label printing and converting. We also make wide format Roll to Roll Hot Foil Stamping Machines for the tobacco industry.

 

The way Abhay Dutta is moving it will not be long before he achieves what he aspires.

Written by Harveer Sahni Chairman Weldon Celloplast Ltd. New Delhi August 2021

 
 
 

Marks Emballage, an international banker’s foray into Label Manufacturing

Marks Emballage, an international banker’s foray into Label Manufacturing
Marks Emballage factory at Baddi

 

In May 2018, the Indian label fraternity was amazed to read the news of an upcoming relatively young label company Marks Emballage announcing the confirmation to buy two Gallus Labelmaster presses in one go. This one step would take this nondescript label manufacturing company into the big league. The author has been in the Indian label industry for over four decades. As far as memory recollects, there have been instances when two presses have been ordered by printers to be delivered one after the other with a gap of time, but the unique instance of two presses to be delivered and installed in just one go is a first one such occurrence so far, this is history for the Indian label industry! By rough estimates, a 4 billion Dollar labels industry (not label stock but finished labels) growing at an average of 10-15% per annum surely needs such investments regularly to meet the 400-500 million Dollar growth in demands of labels. Leading Mark Emballage, Aadtiya Kashyap, a former international banker, is the courageous one who made his foray into the Indian label industry and announced his first significant expansion investment with a bang.

 

 

Aaditya and Khushboo

Aaditya was born and brought up in Mumbai, an Alumnus of St. Xavier’s School Mumbai (He prefers to call the city Bombay as he has called it all his life). Later he finished his graduation from the prestigious Ruia College, Mumbai, in Mathematics. He had considered a career in computers and did a couple of courses in that, but he graduated in the subject since he was good in mathematics. While in Ruia college, he fell in love with Khushboo Singh, who was pursuing BA in the same college. After a courtship lasting almost five years, they decided to tie the knot and got married in 2008. After graduation, Aaditya got his first job in the international bank J P Morgan, where he worked for the next seven years. This job was a good learning experience in how systems in business work and how different departments work. He was the only one in the organization at that time who got four promotions in seven years. Those were many learning years that added to his experience. Looking back, he is happy that he worked there, as the experience has been helping him when in business. 

 

 

 

Aaditya’s wife Khushboo belongs to a successful business family involved in pharmaceuticals, so it was a matter of time that his In-Laws prompted him to consider entrepreneurial options. The suggestions ranged from indulging in pharmaceutical products to items connected to pharma. Khushboo’s grandfather Samprada Singh took it upon himself to mentor Aaditya. Samprada Singh, the founder of Alkem Laboratories, had a significant influence on Aaditya. He was a true visionary and an impactful leader whose life was full of beautiful lessons of courage, resolve, hard work and indomitable willpower. His journey from a tiny village in Bihar to establishing India’s largest pharma company is just an extraordinary one. His life story portrays the old English adage, “From tiny acorns grow mighty oaks.”

 

 

 

Initially, Aaditya spent time in Alkem Laboratories to learn various aspects of the pharma business. First, he spent time with the purchasing team before moving on to “Doctor’s gifting”, a concept that was a contact-building and promotional cum marketing exercise undertaken by pharma companies to stay connected with doctors. A year down the line, he moved to Galpha laboratories owned by his Father-in-law N K Singh taking care of the same portfolio of doctor gifting until a government notification limited the scope of “doctor giftings”. At this time, he faced another change of job profile or considered another line. In his time spent with the purchasing team at Alkem & Galpha, he had gained much knowledge about packaging and its nuances. Khushboo, being born into the pharma business family, was a natural fit to take up professional responsibilities. As business was in her blood, she joined her father’s company, GALPHA which she had joined immediately after college in 2004-2005, primarily taking care of production planning, purchase of packaging and raw materials. The circumstances, as they evolved, led Aaditya to consider making a foray into packaging.

 

 

Meanwhile, Aaditya and Khushboo decided to move to Baddi to set up a pharma unit extension of GALPHA, manufacturing formulations. Aaditya’s experience as a banker kept bringing to him the realization that if two people are doing the same thing, then the output is restricted. He started looking at some other venture. His brother-in-law Dr J P N SINGH (Khushboo’s sister’s husband), who also is looked upon as a mentor by Aaditya, was making pet bottles, suggested label manufacturing and that, eventually led him to decide on labels. JPN had prompted, “all the bottles I make will have labels made by you on them”. His father-in-law NK Singh and grandfather Samprada Singh all agreed that labels were good business. So, in 2011 the decision was taken to set up a label manufacturing unit. The initial two and half years were spent trading in labels, outsourcing them from different vendors and supplying to group companies. During this period, he spent much time with the printers at their factories, getting the right kind of labels and in the process learnt the basics of label manufacturing from prepress to plate making and finally converting. He is indebted to Datta Ram Fulsundar of Aarya Printpack – Mumbai, with whom he had confided about setting up his unit, yet the printer agreed to teach and train him all about manufacturing labels.

 

Since Aaditya had made up his mind to invest in a label press and print labels himself, JPN mentoring him on, suggested; that to test the heat, one should check with just a finger touch before putting your hand in, meaning start the operation at a tiny stage and go thereon. In November 2013, Aaditya, with his wife Khushboo as a partner, launched their maiden startup venture, Marks Fine Printers in Baddi Himachal Pradesh, in a 2000 square feet industrial shed with just one Chinese stack type flexo label press. While Khushboo continued to look after GALPHA Laboratories Baddi, Aaditya got full time into setting up the label unit. The first order, even though it came from a family-owned company GALPHA laboratories, the experience was, as Aaditya says, “Exhilarating! It was like scoring a maiden cricket century.” For the next two years, they catered to family-owned pharma companies. The biggest challenge was getting the suitable operators and people to run the press but then time elapsed, which has taught him to manage that. 2 years after initiation, Aaditya seemed to have tested the heat and confidence, invested in a Bobst label press. Once the operations were well set, it was time to get customers beyond the family companies. The natural step was to rope in companies that were contract manufacturers to the group. Subsequently, they ventured out to service customers outside the family reach, initially it was all pharma as they had much experience in the segment, but later, they got into all segments like Food, FMCG, Liquor and others. He remains indebted to the four mentors that including his father. It is their advice that made this possible. Aaditya always wanted to be like his father, who taught him; “The name that you earn, always has more value than the money earned”.  Walking on his father’s footsteps, Aaditya has ensured a good name for himself along with setting up a successful business. Once established, it was time to get experienced professionals in and systemize the whole operations. They looked around and slowly got their team together.

 

 

 

C K, Aaditya with Ferdi and Sameer of Gallus 

In packaging requirements for pharmaceuticals, the size of labels is relatively small, but when Aaditya started to look at other segments, the label size was much bigger, which meant that with the same inputs and infrastructure, the costing would be different, turnover would grow bigger. This was an exciting realization, and the vision to expand started getting more precise. Initially, Aaditya had planned to add a press every three years, but this new realization prompted him to grow exponentially. He established the new company Marks Emballage Pvt. Ltd. in 2018 to invest in two Gallus label presses in one go. Hoping to make a substantial impact in the Indian label industry with their big move, however, as luck would have it, they started printing on these two presses in April 2020 when the pandemic hit across. Covid has been a difficult time for Marks Emballage. The first few days were a mixture of too many different feelings inside, from the fear of the unknown, concern for employee’s safety, responsibilities to serve the customers. Despite the uncertainties, they gathered themselves and planned to navigate through the difficult time. This was possible only with the total dedication of their team, who put up great courage and kept the business going and growing. They realize that going into the future, leaner companies and more automation will be the way forward. Cloud technologies, robotics, artificial intelligence, and virtual reality combined will reduce human physical contact and dependence. This will be the biggest shift for all businesses and Marks is no exception. This goes on to validate their investment in the right equipment, processes, certifications, and team.

 

 

 
Besides having residence in Mumbai, Aaditya and Khushboo now stay in Chandigarh with their 8-year-old daughter Kiara. While they complement each other in work yet look after different businesses. Marks Emballage Pvt. Ltd. is a fast-growing company headquartered at Chandigarh and operates out of factories at two locations in Baddi. The plant is spread over 30,000 square feet and equipped with some of the finest equipment like print kits from Gallus, Bobst, AVT, Prati , Pantec and Xrite. A team of 60 people is creating a work culture of excellence. Talking of new ideas and projects and the vision for the next five years, Aaditya says, “We have too many ideas to implement. I am working on many exciting new projects in technology, consumer products, packaging, and pharma. We aspire to roll out at least one new project every year for the next five years. This is the time for us to spread our wings before getting into a consolidation mode in 5 years. 
 
CK Gadhia of Marks giving student of year awards
 
 
 
The journey has just begun”. Marks Emballage has, as a part of its CSR initiative, invested in sponsoring the annual “Printweek Student of the year” award. They are very keen to backup educational initiatives for encouraging the new generation to take up print as a career. 

 

 


As he plans his way forward in the label and packaging field, Aaditya makes a fervent appeal to peers, “I would like to appeal to all the fellow label printers that we should all work with better collaboration and work with each other rather than work against each other. Together we can have great strength to backup print education to ease our recruitment needs, have complimentary print technologies to avoid idle capacities, and have a better say in purchase or sales negotiations. The advantages are just many. It is time to team up and grow the industry together. We need to increase the overall pie. While we are all doing the basics of waste management today, the need of the hour is to attack the problem from the very base. We are studying and closely following linerless labels and believe that they can be a game-changer for our industry. As per industry reports, only 5% of the laminates and self-adhesive label stock is reused or recycled. This area demands our closest attention. 

 

 

 

 

 

 

 

 

Marks Emballage is a company to watch, as an ambitious team aspires to grow 10-fold by the end next five years. With a young, dynamic leader like Aaditya Kashyap at the helm, hoping the pandemic’s after-effects soon end, this company will be moving fast to achieve targets and move tangentially, investing in technologies in synergy.

 

 

 

 

 

Written by Harveer Sahni Chairman Weldon Celloplast Limited New Delhi July 2021

Combatting the more vicious Covid-2

Combatting the more vicious Covid-2
The continuous wailing of ambulance sirens, send a chill down one’s spine, another loved one from somebody’s family, suffering from the impact of second edition of covid-19, is on the lookout for a hospital bed and the much-needed evasive supply of oxygen as life support. It is ironic that in today’s time of technological advancement many unsuspecting innocent human beings are losing a desperately fought battle for survival against a more vicious and fast spreading variants of corona virus. Medical infrastructures are crumbling under the huge volume of patients reporting infections. Vaccination program is struggling to meet targets that keep becoming difficult by the day, the government has opened registration of people for vaccination, but it is a gigantic task which presently at the very outset, means reaching out to over 50% of the total population of almost 1.4 billion people which would be about 70 million people spread across a large geographical terrain in 29 states and 7 Union territories. Recently a newspaper reported the registrations for vaccinations coming at the rate of 55000 per second! A bigger danger is that much of rural India which accounts for almost 65% of the total population (90million) was largely unaffected and now the virus seems to be creeping there as well. The problem is not only India, as in today’s time given the travel mobility of people from all walks of life and with their relatives spread around the globe with different natural and adopted nationalities, the present dangerous second phase of the pandemic is a global problem and unless checked, it may reach very scary levels impacting the world at large. The second wave is so vicious that it has impacted every other home. It is heart-warming to see that governments around the world understand the problem and are coming forward to cooperate with each other in combatting this menace. On the domestic front we see religious bodies, NGOs, industry and many others doing their bit to defuse the pain and anguish due to the impact of the pandemic. The Indian label industry is also taking steps to contribute towards the safety and wellbeing of their workforce and wherever possible contributing to the society as well.

 

 

Kuldip Goel
The author reached out to many leading label manufacturers to assess the level of infections in the two phases of covid and their reactions to combat the menace.  The author, his most family members including both sons K D Sahni and Pawandeep Sahni, MD of Omet India Pvt. Ltd. and 4 employees in his company Weldon Celloplast Ltd. tested positive. Kuldip Goel president LMAI (Label Manufacturers Association of India) and Chairman/MD of Any Graphics NOIDA  reported 25 of his team including 14 of top management along with his son Naveen went through the ordeal. He restricts himself from saying he helped his people during the hard time but prefers to use the word support instead. Besides ensuring the job security of his people, providing financial and medical support they even arranged counselling to almost 100+ people in bringing them out from depression. Kuldip along with his colleagues in board of directors of LMAI are already planning to import Oxygen concentrators for the needy. Abhay Datta Director UV Graphic Technologies where 4 people were infected including himself and his son, has prepared guidelines and implemented them for awareness and safe working within the business. He has developed UVC disinfection devices for articles to contain spread of corona. He is unhappy on how the government has dealt with the outbreak, he says, “It is a bad situation, really sad that the government has failed to control it.” Twelve persons including himself and his plant head in Anuj Bharagava lead Kumar Labels suffered infection, but Anuj went ahead and made a makeshift clinic with Oxygen & IV facility at his NOIDA factory. As also helping communities by enabling concentrators and oxygen cylinders. He too is concerned about the handling of the spread, “It is a terrible period for India, and humanity. We wish things were better anticipated and planned by the authorities. However still, we are all doing our best to help each other. Sad to see some people trying to profiteer by selling drugs and services in black” he says.

 

 

Nirav Shah
In central and west India there is a bigger concentration of label companies and there too most are impacted though some have succeeded in limiting the impact of the pandemic.  LMAI honorary secretary and Director of Indore headquartered Pragati Graphics and Packaging has been deeply involved in arranging hospital beds, medicines, oxygen, oxygen cylinders, etc. for a lot of people from and around Indore. He has also arranged two oxygen concentrators which are being given to needy people. Commenting on the 25 people infected in his company he said, “To me the picture looks gloomy. The industry was slowly picking up as the demand was growing. This wave of pandemic has again brought the industry to its knees and the situation will become very bad if the wave of Covid does not recede soon.” Nirav Shah heading Letragraphix in Ahmedabad had to re-engineer his production plans to meet timelines and service his customers efficiently since 20-25% of his workforce got infected. He has stood by his employees in full even during lockdown and providing whatever support was needed. On the social front Nirav finds satisfaction from the fact that they have donated sanitisers, ration kits and food packets besides supporting an NGO called Karma Foundation on regular basis. He states that these are unpredictable times which have taught many lessons to everyone to get adjusted to a new normal of work culture and pray for the world to heal soon.

 

 

 

Vinod Vazhapulli of Skanem
Mumbai based Skanem India Pvt. Ltd. (Formerly Skanem Interlabels) a subsidiary of Skanem AS headquartered in Norway with presence in 8 countries also reported 15% to 20% of workforce as infected in its 4 sites within India. Vinod Vazhapulli Managing Director informed that the company has taken care of their employees by paying before time in full without any deductions whatsoever ever since the start of pandemic and supporting wherever help was needed. The company had them covered under the Insurance scheme with a coverage of Sum insured of Rs. 2 Lakhs especially for Covid by Skanem India, thereby ensuring that all their Medical and treatment expenses are taken care of under Cash less transaction schemes. Online counselling sessions / Yoga classes etc. were organized ensuring that any kind of anxiety or mental dis-order that would have developed due to the pandemic or extended lock downs are handled by experts, taking care of the mental wellbeing of their employees. As a social endeavor They have provided Medical aid , Food & PPEs to the Maljipada village where the Mumbai plant is, during the peak of Lock downs last year. Vinod says, “ there has been an impact of this outbreak on our Industry, the recovery had commenced but with this 2nd wave it is again pushed back to uncertain times”.

 

 

Raveendran
South India based Rajeev Nair CMD of Stallion Group informed that 25 % of their team including 5% from management were impacted, he is worried that the business that went down in the first phase of covid had started to recover is now again adversely impacted in the second phase. Raveendran of Seljegat in Sivakasi is thankful that they have been cautious with their workforce, so the infections were minimal, just two employees and his younger brother were impacted mildly and recovered. They have in place a strict protocol of checking temperature, oxygen levels and providing sanitisers. They also provide herbal immunity boosting tea to all workforce who must maintain safe distance and are divided into two shifts. Except for a week of lock down, they have been working right through and in fact are in 100% production. They provide separate buses for women and other workers making several trips to maintain distance and transport them to and fro safely. They have even invited government officials to study their systems that have helped in curtailing the infection. We see similar situation in J K Fine Prints Mumbai, Director Himanshu Kapur who is son of Surender Kapur the founder president of LMAI says, “We had just one infection between the two phases, we have given full financial support to our workers as also provided them and their families with masks, sanitisers and other needs” he further adds, “After the initial jolt, I now feel that label industry will not be so drastically impacted. We  will see  growth coming from Tier 2 and Tier 3 cities who will patronise organised retail for their needs”.

 

 

Sandeep Zaveri of Total Print
 
The best response came from LMAI past president Sandeep Zaveri heading Total Print Solutions Pvt. Ltd. Mumbai, he says, “Between the two phases none in our company got infected due to strict norms maintained by us and supporting our team with full salaries and food needs” he adds, “I think God has created this for us all human beings to go slow, spend quality time with our near and dear ones”.

 

 

 

 

Many NGOs(Non-Government Organisations), religious bodies, companies and individuals are contributing in whichever way they can reduce the sufferings of people. Donations and help from these groups keep pouring in and exhibits the caring that emanates from these groups. However, in contrast we have reached a situation when politicians continue to play the blame game accusing each other for the sufferings of population, with their eyes on the next election and access to country’s coffers they are insensitive to the pain people are going through. Allowing election rallies and religious gatherings of hundreds of thousand people not following covid norms has contributed to the massive spread. The central government says state government is wrong and vice-versa while the innocent citizens gasp for that breadth which will come loaded with some oxygen so that they may still survive to be with their loved ones another day. It is so unfortunate that we talk of financial outlay of billions in our budgets yet a commodity like oxygen that is an imperative for survival has become a political point for our leaders blaming it on logistics. The pain and suffering do not end for the relatives of those who have lost their fight against covid and passed away, there is neither the means to take the bodies to cremation grounds nor the space to cremate them. Will residents of another developed country understand this kind of situation?  All this while the needy yearn for that breadth which will decide if they exist the next day or not. Added to this the unscrupulous citizens who look at this as an opportunity to make more money, they make the Shylock in Shakespeare’s story “Merchent of Venice” appear as a reasonable person, he may have just asked for a pound of flesh from just one borrower, here these black marketeers are trading in oxygen, essential medicines and life support equipment to draw unreasonable profit from the lives of a suffering generation. 

 

 

History will not and should not pardon such unethical persons who have no feelings that a grandparent, a parent, a spouse, a sibling or an offspring are so  precious part that one yearns for them to be there always and losing them is not imaginable. Courts in India appear to be understanding the gravity of the situation but who will teach the politicians who are the executive running the country. It is not just watching on TV that people are suffering and dying, but it is now being felt and being experienced by all households largely. A friend, a relative, a business associate, a colleague or a loved one just vanishes losing out to the pandemic leaving a void and a hollow feeling whereby the tears have no place to go.

 

 

Written by Harveer Sahni Chairman Weldon Celloplast Limited New Delhi May 2021

Reproduction permitted by giving credit to author and link to blog http://harveersahni.blogspot.com 

 

“Evolving and shifting trends in self-adhesive labels”

“Evolving and shifting trends in self-adhesive labels”

In my early years when I worked for my parental company Weldon Sales Corporation established in 1939, manufacturing stationary products like Weldon Fountain pen inks and office glues besides a range of stationary products, I remember that we used to affix paper labels on glass bottles using water-based adhesives. Initially these were solutions of gum Arabic and later we switched over to starch based adhesives produced by us captively. These worked well on glass bottles or paper-based packaging, the only challenge was that we had to wait for the adhesive to dry before putting these into secondary or tertiary packs as the labels would shift if packed wet compromising the appearance of the product. The same issue was encountered by the beer industry which continues to face it, at least for some brands that still rely on adhesives that do not address this problem. Since glass packaging was heavy and was susceptible to breakages in transit the introduction of plastic HDPE (High Density Polyethylene) bottles came as a big relief at that time. HDPE that was invented in 1953, started being initially imported and later produced in India by Polyolefin Industries Ltd. a Mafatlal Group Company under license from Hoechst Germany, in the late 1960s. HDPE plastic bottles came as a big innovative development for the liquid packaging industry. When we at Weldon started using outsourced Plastic bottles, later manufacturing them in-house, labeling them brought fresh problems.

The labels affixed with water-based adhesives, on drying would fall off in transit or get wrinkled. This was because of the reason that HDPE is a low-energy polymer and for normal water-based adhesives to form a permanent bond is a problem.  For some round bottles, we started using wrap-around labels as then the label would come around and get pasted paper to paper. It was during this period after 1965 that the earliest self-adhesive labels started being produced in India and in the 1970s their usage in the packaging of products started to increase. These labels would bond instantly, would not need drying and would not shift in packaging , also aiding the aesthetics so their usage spread quickly and widely. It was that time we at Weldon also shifted to self-adhesive labels or pressure-sensitive labels. The rest of the evolution of Self-Adhesive labels is history and is still an ongoing process.

Adhesives: Pressure-sensitive adhesive(PSA) labels is now one of the fastest growing segments in a world of diverse labeling technologies. It provides accuracy of clean labeling and options to use a variety of adhesives for  application on different surfaces in most environments, including temperature, humidity, exposure to UV, etc. Advancements in products and their packaging require labels to perform in extreme and demanding parameters.

Some food and pharma products require the labels to perform at very low temperatures, typical are for ice cream, pharma and vaccines that require extremely low temperature for storage. Synthetic adhesives that are in use nowadays harden at very low temperatures and tend to fall off so must be formulated to withstand the application and storage conditions. These adhesive soften at high temperatures therefore signages and labels that must be used for outdoor in diverse environments, withstand UV light and heat build up due continuous exposure to sun also need adhesives specially formulated to perform for the duration of their lifetime. Direct PSA labels application on food products like fresh fruits and vegetables is now in use and labels must be certified safe for direct food contact and that they should not have adhesive or inks from which plasticizer may migrate into the product. Coming to labeling on low energy surfaces like HDPE bottles mentioned above, though the label sticks well but in these days of increased incidence of anti-counterfeiting, pilferage and tampering, the label with standard general purpose adhesive can be pulled off cleanly by an experienced hacker or counterfeiter. So, the adhesives are an important and integral part of evolving trends in self-adhesive labels. A lot of development has been done on these lines and continue to be taken up to produce special formulations that conform to the specific requirements.

Substrates and embellishments: As customers grow in numbers, segments, literacy, urbanisation and geographical spread, the packaging development managers are attempting to create innovations in partnership with label printers to woo the consumers, increase the shelf appeal of products and increase brand recalls.

Moving from simple label substrates like uncoated maplitho or uncoated woodfree paper, now the selection of substrate is as per the imagination or creative ideas of the label developers. The label face materials can be selected from a wide range of options available like semigloss paper, metallised papers or films, textured paper, various clear or opaque films, fabric, cork, lenticular films, holographic paper or films and anything that emanates out of a creative designer’s mind. As for embellishments, there was a time when either using a cast coated paper or a good varnish were the only options, but now a whole world of new ways to embellish labels has erupted. Using multiple printing technologies to get the best of every printing process, adding value to win customers and beat competition is becoming a necessity for printers. Today we see labels being made in-line in a single pass employing a combination of flexographic printing for spot colours or pantones, offset to create vignettes or skin tones, screen for higher deposition of ink, rotogravure to get the best results of metallic inks, cold foil, hot foil, using a variety of varnishes to create effects like textures, high gloss, matt, silk finish or just spot varnish, embossing and debossing to bring amazing results in the finished labels. We see printers create labels with raised effects like dew drops, print that seems to give the look and feel of wood and fruits with pulp, giving a natural effect. Adding further to the capabilities, now printers are employing digital printing either in combination as mentioned or as repass to do variable printing and or personalization. The options are getting to be limitless.

Security Labelling: Increasing number of instances of duplication, counterfeiting and pilferage has created a need for security to be made an important part of labeling.

Counterfeiting products is a problem not only limited to pharmaceuticals industry, but it also affects 5 to 7 percent of global trade. It has impacted other industries as well, such as electronics, automotive parts, spirits, consumer products and high-end cosmetics. Earlier security labels were only with security cuts incorporated at the time of die cutting, then specialized stocks with overt and covert features like the Void labels started being used followed by destructible labels. Holograms also have been largely employed and is now hologram production is a large segment of label industry. With development in pre-press and printing technologies printers use micro printing which is not visible to naked human eyes and other such printing methods used in printing currency to inbuild security in labels. Barcodes are also being largely employed to play an important role in security in labels besides aiding variable statutory information, track n trace information, inventory and logistical data. A very important development in recent times has been Intelligent labels that include near field communication (NFC) or radio frequency identification (RFID) to perform a wide variety of tasks. Integrating these capabilities with traditional labels is one of the most dramatic development in labeling.

Printing Equipment: The narrow web self-adhesive label manufacturing commenced in India in the first half of 1970s on small, about 4-5inches label presses imported from far eastern countries mostly from Japan at that time. These small narrow web presses that did block printing were extremely slow about 5 meters per minute but still did the printing and die cutting inline in a single pass, that was its USP.

It may appear strange to the younger printers of today that there were no drying arrangements in these presses. Printers would print and then hang the printed rolls of labels on a clothesline for drying before rerolling them on a core and sending to customers. Shop floors of narrow web label printers would look like washing yards referred to in India as “Dhobhi ghat”. The printing technologies with time went through continuous changes. The flatbed block printing made way for semi-rotary intermittent letterpress using polymer plates. With improvement in Flexo ink and plate technology, rotary label presses with central impression drum (CI Label Presses) found their way into print shops. These provided faster speeds at increased widths of 7 inches(180mm)-10inches(250mm) and as the buyers became more demanding on colours, speeds and performance, together with further evolution of prepress, advancements in plate making and registration controls, the CI narrow web label presses moved out making way for modular presses using water-based inks with hot air dryers. However, CI presses continued to be used for other applications like lami-tubes and mid-web flexible packaging. Label presses have over the years evolved to print wider web widths of 330mm, 430mm, 530mm and at last Labelexpo presses over 650mm were displayed. Printing speeds have also escalated to over 200meters per minute. In an evolving scenario of rising demands for perfection in print and printers facing challenges in reproducibility, colour variations due to viscosity changes in ink trays and set up wastage, were releived when UV inks, UV lamps for drying and short web path became a standard part of presses. The UV printing also enabled printing and converting filmic labels after addition of corona treaters inline to enhance print adhesion. Some label companies have of now reverted to include a combination of hot air and UV as some food products have witnessed migration of photo initiators in UV inks migrating into the food causing contamination, so the option to print with water-based inks comes in handy to service such requirements. LED UV also is being seen as replacement as there is energy cost saving and better as regards migration issues. Ideal solution maybe Electron Beam curing which is costly but that has still to be accepted by Indian label industry. There is hardly any installation with EB curing for production of narrow web labels in India.

Other evolutions that happened include label presses designed for quick change overs to enable a large number of jobs per day, servo drives to eliminate gears coupled with advanced vision camera systems to achieve perfect registrations in both machine and cross direction without human intervention, better matrix removal, web cleaners to eliminate pinholes and print aberrations, web turn bars to print both sides of the web along with the delam-relam function for enabling printing on back or the adhesive coated side of the web. Movable lamination stations and embellishing stations like foiling add value to the printed labels. Multiple die-stations to enable functions like embossing, debossing, slitting besides simple die cutting or sheeting have become a standard function demanded by high-end printing companies. Change of heavy magnetic cylinders was a cumbersome and time-consuming job requiring manpower and lifting arrangements. Now in a couple of minutes one can slide-out and slide-in a magnetic cylinder.

The pandemic that surfaced in end of 2019 and drastically impacted the whole world and made businesses suffer for all of 2020 and when we are hoping for it to taper off in 2021 providing relief to mankind, it has started to resurface. It has prompted the industry to re-engineer their working. The aim now is to work with less. Workflow management, increased automation, clean room manufacturing, inventory controls, effective management systems, etc.  are the buzzwords that even smaller entrepreneurs understand and are making efforts to implement them.  Automatic butt slicers/reel changing systems to achieve continuous 24X7 production when needed, waste management equipment sucking waste matrix right from the die cutting stage and shredding and inline inspection/colour management systems to reduce rejections which were earlier a preference of only a selected few, but these are now a part of standard equipment configurations envisaged commonly by Label printing  companies planning expansion or planning new setup. The evolution and shifting of trends in self-adhesive labels have been an ongoing process and printers need to adapt the changes as they originate to stay fit, competitive and innovative.

Author’s footnote: Each parameter listed above and many other parameter’s like inks, special adhesives, coatings and machine design are subjects that are to lengthy to be accommodated into one article and need separate coverage. 

Written by Harveer Sahni, Chairman Weldon Celloplast Limited, New Delhi-India April 2021