At Plastindia 2026, Daetwyler SwissTec presented its latest developments in doctor blade technology, reinforcing the role of high-performance doctoring systems in improving print stability, ink transfer efficiency, and press uptime for gravure and flexible packaging converters.

Speaking to The Packman, Markus Resing, deputy head of marketing and sales, Daetwyler SwissTec, detailed the company’s latest product introductions, portfolio expansion strategy, and its long-term roadmap for the Indian market.

Longlife Pro – optimized doctoring for high-speed gravure

Daetwyler’s key product highlight was Longlife Pro, an advanced variant within its coated doctor blade portfolio. Positioned as an extension rather than a replacement of the existing Longlife range, Longlife Pro is engineered to deliver enhanced wiping consistency, particularly on autogravure cylinders operating at high line speeds. “This is not replacing the existing Longlife blade. It is an additional option for customers who need even higher wiping quality,” Resing said.

The blade incorporates a dual-layer coating system, combining a ceramic base coating with a second functional layer that reduces friction at the doctoring interface. This design minimizes blade and cylinder wear, stabilizes ink metering, and extends blade service life. According to Resing, “the second coating makes the doctoring much smoother and protects both the blade and the cylinder.”

A major technical enhancement within the Longlife Pro platform is the Rototip lamella configuration. This alternative tip geometry, developed as an option to conventional multi-blade lamella designs, improves contact uniformity and ink removal across the cylinder surface. “Rototip helps eliminate hazing and toning and improves wiping stability, especially on high-speed presses,” he added.

Portfolio expansion through analogue plate integration

Beyond doctor blades, Daetwyler is expanding its scope as a systems supplier. The company has acquired a UK-based manufacturer of analogue flexographic plates, now fully integrated into Daetwyler SwissTec’s global operations. While the integration will be phased, it enables Daetwyler to develop a comprehensive solution portfolio for flexible printing. “In the future, we want to offer complete packages for flexible printing – doctor blades, analogue plates, end seals and accessories,” Resing said.

Coating technology and its impact on print performance

Resing emphasized that coated doctor blades play a critical role in ink transfer efficiency and print stability. On rotogravure cylinders, uncoated blades are more susceptible to ink build-up, which can lead to haze, ghosting, and tonal variation. The coated surface of Longlife Pro reduces friction and improves wiping precision, resulting in cleaner cylinders and more consistent ink films.

The second functional coating layer further enhances surface smoothness, reducing edge wear and lowering the risk of scoring or premature blade failure. This translates into longer blade life, fewer blade changes, and reduced press downtime – key performance indicators for high-volume packaging printers.

Operational best practices and common errors

Resing identified three operational factors that significantly influence doctoring performance. The first is system cleanliness. Residual ink or contamination in the doctor blade holder, support blade, or chamber assembly can compromise wiping efficiency.

The second is mechanical alignment and dimensional compatibility between the doctor blade, support blade, and holder. Deviations from recommended geometries can result in unstable doctoring and accelerated wear.

The third, and most frequent, issue is excessive blade pressure. Once contact with the cylinder is achieved, only minimal pressure is required. Overloading the blade increases friction, shortens blade life, damages cylinder surfaces, and negatively affects ink metering.

Enhancing global competitiveness of Indian converters

Resing noted that Indian converters face increasing quality and consistency demands from global brand owners. Advanced doctor blade systems help address these requirements by reducing process variation and enabling higher-quality output with lower waste.

Although coated blades carry a higher initial cost, their extended service life and process stability reduce the total cost of ownership. Daetwyler supports this with cost-performance calculations that demonstrate long-term savings compared to conventional uncoated blades.

India is one of Daetwyler SwissTec’s fastest-growing markets globally. “India is not yet our biggest market, but it is our fastest growing one,” Resing said. “In the future, it could become one of our largest.”