“From Cartons and Commercial Printing to 100% Labels!”

“From Cartons and Commercial Printing to 100% Labels!”

Narinder Chhatwal hailed from a family of traders in Lyallpur, a city which is now in Pakistan after the partition of India in 1947. Lyallpur was named after the founder of the city the then Lieutenant-Governor of the Punjab, Sir James Lyall, for his role in establishing the canal colonisation project. In 1977 the Government of Pakistan changed the name of the city from Lyallpur to Faisalabad (‘City of Faisal’) in honour of King Faisal of Saudi Arabia, who made several financial contributions to Pakistan. Faisalabad is the third-most-populous city in Pakistan after Karachi and Lahore, respectively. It was in the turbulent times of 1947 during the division of India into India and Pakistan, that the Chhatwals migrated to New Delhi. After completing his schooling, Narinder Chhatwal took up a job in the iconic Kwality Restaurant in coveted location, New Delhi’s Connaught Place, a venture set up in 1940 by P L Lamba and his brother-in-law I K Ghei who grew it as a multilocation restaurant chain. Narinder worked there until 1961. There was a strong urge to have his own business, so he set up a unit to produce ice cream cups but as situation warranted then, he left this venture and rejoined Kwality Restaurant yet again in 1964. Despite the stable job, the entrepreneur in him was restless and the urge to set up his own production unit re-surfaced and he finally quit the job permanently to start a printing unit nostalgically named Kwality Carton Manufacturing Company, in a single room rented at Kirti Nagar, New Delhi in 1966-67 using the manually fed treadle letterpress printing machine. He manufactured Ice cream cups, lids, cartons for Ice cream bricks and in fact a host of printed packaging items. In 1971 he could get an allotment for an industrial plot from government at Naraina Industrial Area and he moved the unit to this location where from, they operate to this date.

 
A little over a year after moving into their Naraina factory they bought their first offset printing press, a 712 single colour Dominant, a year later they bought another similar press and followed it up with a 714 Dominant. Falling short of space, the adjoining building was available, so they bought it as they were growing. In 1982-83, expanding further they acquired a two colour Planeta. Once into offset printing, Kwality was in expansion mode, they were adding equipment every alternate year. At this time, they renamed the company as Kwality Offset Printers. In 1986 Narinder Chhatwal’s son Rajeev an 18-year-old had joined business. Rajeev did his initial Schooling at Springdales School Delhi followed with graduation from Delhi University. The post partition Punjabi families who left all that they had, back in what had become Pakistan were hard working and were quick to start from scratch to regain their stature by sheer hard work. The second generation were all following their father’s footsteps and would be helping their parents in the work, spending time after school or college on the shopfloors of their startup units. For them, the shop floors became the training ground, and they learnt the nuances of business hands on. Rajeev was no different, with a  father like Narinder mentoring him and passing on the experience to his son who was a quick learner, he settled down in the business quickly. He however did go for a short training program at Heidelberg Germany. With his joining in, the business accelerated and soon the space in their Naraina factory was again falling short. In 1988, they bought out yet another next-door unit to make room for more production space so now the factory is operating from three adjacent plots. The same year they bought their first four colour offset press a secondhand Roland. Expansion became a routine process. They believed and were convinced that as far as possible it is better to operate from a unified single location in one city. This way the management which was Narinder Chhatwal, and his son Rajeev Chhatwal were not split and would remain a support to each other.

 

 

Until 1995 Kwality offset was producing Cartons, some commercial printed items and wet glue labels. In 1995-96 they decided to become a hundred percent label manufacturing unit which was only wet glue labels. The story of their entry into wet glue labels is interesting. In the early 1990s when the number of breweries started to grow and bottling speeds were on the rise. To label bottles at 250 bottles per minute, the labels needed to be perfectly die punched and stacked to run on highspeed lines. The normal flatbed dies would not work well. Kwality, because of their experience in ice cream cups and lids production were well versed in ram die punching and their workers were well trained in the process. Their manufactured labels ran extremely well on the high-speed labelling machines at breweries and distilleries and soon the word spread of their capabilities. This helped them get the orders from many other breweries and liquor producing companies. It was just a matter of time that they became the largest suppliers of wet glue labels in north India, though they were supplying pan national. It is interesting to note that normally people print and then get into label finishing equipment, here because of their knowledge of finishing the ice cream cup lids by hydraulic ram punching got them into high end big volume label printing. Their first customer for beer labelling was a government owned Haryana breweries at Sonepat making a popular brand of beer those days “Rosy Pelican.” Their success in making the perfectly die-punched wet glue labels also got them their first break in corporate world with orders from the multinational brand owner Nestle.

 

 

It was in the year 2000 when self-adhesive labels were gaining in popularity, the Chhatwals invested in a Mark Andy 2200  narrow web label press and in the following year, they also increased their investment in sheetfed offset by installing a six colour Heidelberg press. In 2002 they installed another sheetfed offset a five colour Roland with UV and online coater. Hereon, expansion became an ongoing process, they added three Mark Andy presses, a Gallus and a Xeikon in 2018 to make their entry into digitally printed labels with an ABG Digicon series 3 finishing and embellishing machine, which also has hot foil stamping , embossing and screen-printing capabilities. These investments enabled them to add multiple security features on labels. Increasing their footprint in flexo they also set up inhouse platemaking with Kodak Flexcel. Rajeev’s father Narinder Chhatwal passed away in 2008 until when, he was still attending business, though the reins had been passed on to his son Rajeev.

 

 

Rajeev’s other siblings include a younger brother who is into real estate and a sister who is a homemaker. His wife Shalini is also a home maker. His son Krish completed his business management from Sydney and joined business at Kwality offset four years ago. Two of those initial years were passed in facing the pandemic and last year in 2021 he got married. Krish’s wife Sanya, an expert in baking, after completing a course from APCA Malaysia, is running her own business, a bakery named Delhi’ce in Gurgaon making specialty cakes. Rajeev’s daughter recently completed her study in architecture and is now pursuing her career as an architect.

 

 

Having put in place a full-fledged team to manage all production, Rajeev, and son Krish personally look after sales and marketing. While Krish looks after all new customers, Rajeev manages and caters to, and successfully retains all old customers. The present spread of business is with three flexo presses, one digital label press Xeikon, Abg digicon, one Roland and one Heidelberg sheet offset press in a shopfloor admeasuring approximately 60,000 square feet. Total workforce is 130 persons all in one location at Naraina Industrial Area New Delhi. With no more space left for expansion at present location, they have bought a 2200 square yard plot at Manesar south of New Delhi for another factory to fuel their further expansion. When asked about future plans, Rajeev expresses that they are not really concerned about just volumes, they are more oriented to implement better and innovative technology and be profitable to grow the bottom line instead of focusing on bigger turnovers. Kwality has been growing at about 10 percent per annum and they are committed to maintain the growth rate. Conscious about the environment they have tied up with approved and certified waste management agencies as also cooperating with Avery Dennison on their waste management endeavours. They even try and source most of their paper materials from FSC certified vendors. Despite the aftereffects of pandemic, the father-son team are committed and firm to keep the expansion and investment in new technologies an ongoing process. Their resolve years ago to give-up cartons and other commercial printing to stay with 100% manufacturing of labels is unique in today’s situation. These days offset printers do integrate forward to produce labels and vice-versa label printers, in an effort to grow turnovers, expand into print packaging. They wish to remain specialty label printers, investing into innovation.

 

Written by Harveer Sahni, Chairman Weldon Celloplast Limited New Delhi March 2022

PS: Printing Magazine may publish this article giving credit to author Harveer Sahni and Blog https://harveersahni.blogspot.com  

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