Integration and development of a large printing and carton packaging factory
An associate company of VK Global Publications in Faridabad – VK Global Digital, a well-known manufacturer and supplier of holographic metallic effects, acquired RaveScan at NCLAT in 2018. We recently visited the factory in Manesar, where VK Global Digital integrated all assets in the RaveScan factory in Manesar and the Naraina industrial zone in West Delhi.
The assets acquired by VK Global Digital are considerable, including nine Heidelberg offset presses, including seven multi-color presses, ranging from four-color to eight-color presses, as well as one two-color and one single-color printing press. Several printing presses are equipped with a coating machine, and the 6-color UV printing machine with a coating machine is equipped with an in-line cold foil unit on top of the first two units.
For finishing, coating, laminating, binding and processing production lines, there are separate floors dedicated to commercial printing and binding, as well as packaging processing for single carton and luxury carton manufacturing. In the field of commercial printing and post-press, VK Global has devoted more than half a year to the printing of school and university textbooks. However, it is equally urgent to fill this comprehensive binding capacity with ordinary books. The equipment is first-class, from a large number of folding machines, Aster partial sewing machines, Muller Martini automatic collection and stitching machines, to multi-clip perfect binders and 3-knife trimming machines.
VK's commercial printing department in Manesar has expanded its book printing capabilities with a complete set of monochrome, two-color, 4-color, 5-color and 8-color perfect Heidelberg presses and a wide range of automated binding equipment. Together with VK Group’s school and university textbooks, a lot of money has been invested in the textbook season. For the rest of this year, it is seeking to generate more demand from general book publishers and advertising materials, especially from its existing customers for whom it has already provided luxury packaging in single cartons and hard boxes.
Namit Jain, director of VK Global, told us that the packaging department of the Manesar plant is driven by Heidelberg 6-color coater UV printing presses and other multi-color coaters with conversion equipment, including precision register laminators and Bobst Novacut die-cutting machines And two Bobst folder-gluers. Jain explained: “In the first 15 months after taking over the factory, we carried out a simple reorganization of the factory and transferred all the equipment, including the Italian hard box manufacturing machine, to the single large plant we occupy today in Manesar. .It can be said that this is a period of healthy learning and consolidation, and then the pandemic strikes.
Nonetheless, in the past 18 months, we have been fortunate to be able to establish strong connections with customers who are critical to consistency and timeliness. But we must increase productivity to meet their needs. For this reason, we increased the efficiency of die-cutting and purchased another folder-gluer from BOBST. However, even after optimizing the productivity of our Novacut die-cutting machine, we still need more capacity to balance and increase our carton throughput, so we have already ordered another Bobst Novacut and are eagerly waiting for the same Delivery. "
It is true that with the global pandemic raging, it is a considerable challenge to turn around a large printing and packaging factory in less than three years. Namit Jain humbly admits that the factory is now in a state of operating balance and is undertaking a more difficult task, which is to upgrade operations and systems to achieve expansion, growth and healthy profits.
VK Global Digital, the parent company of the Manesar commercial and packaging plant, produces a unique film that contains a spectacular metallic holographic effect that can be laminated to a board or the carrier film can be completely removed for recycling. Although these films have been mainly exported in the past seven years, and some global brands and leading processors have also shown interest in India, Jain said, “Now is the time to develop the Manesar factory and introduce this decoration and anti-counterfeiting technology to the Indian market. The Indian carton packaging market. We have applied it extensively to the textbook covers produced by our publishing company, and now we hope to introduce these attractive metal effects into Indian carton production more and more.
"Considering our experience in film production and the comprehensive technology and application equipment of our Manesar plant, our unique metallic effect film and its application on paper and cardboard may be the only such capability in the world. It Already used by leading cosmetics manufacturers in Europe, it should be a sustainable and eye-catching solution that can maximize shelf impact and prevent counterfeit and shoddy products from our Indian customers. It can become laminated metal on board The easy-to-recycle solution of polyester film is called met-pet by the industry."
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