Vadodara-based Ganga Stereos has installed an Esko CDI Spark 4835 flexo imager (HighRes with 25 Optics) in a bid to produce high-quality flexographic plates. The company has also opted for Imaging Engine (RIP), Deskpack Flexo tools and a Dupont Cyrel 1000P solvent processor. Muthu Kumar of Ganga Stereos said that the investment will help him to expand his client portfolio while enabling him to serve both labels and flexible packaging segments in addition to corrugated and woven bags industries that he has already been catering to.
Ganga Stereos has been manufacturing various stereos including flexo nylo, white polymer and molded for the past 23 years. The company started its operation by making hand-engraved flexographic plates that it supplied to neighboring markets. Later on, the company also started manufacturing polymer blocks, paper and woven bags. In 2010 the company moved to its own premises and was making plates using traditional analog plate-making equipment until it invested in the Esko kit. Happy with the performance and productivity of the new kit, Ganga Stereos plans to phase out its conventional plate-making system in near future and go completely digital.
“Producing high-quality plates on an analog plate-making equipment system is a huge challenge. In addition, there are few suppliers left who provide the raw material for making plates using conventional equipment. Even the raw materials cost is increasing every day. Now with the CDI Spark 4835, we will be able to optimize quality and produce high-quality flexographic plates cost-efficiently in less time. Besides, the CDI flexo imager gives us the freedom to work with the plate vendor of our choice,” said Kumar. “In addition, we can make plates for different markets from tag and label, flexible packaging, small and medium folding carton to corrugated market. We invested in the Esko kit because we were looking for a simplified prepress solution that can be implemented fast and used with a reduced amount of training.”
Since the installation of the Esko kit, Ganga Stereos has started supplying its plates to labels and CI flexo printers. Kumar said, “Earlier since there was not any digital flexographic plate making company in Vadodara and its nearby areas, customers used to get their plates from Mumbai and Ahmedabad. But now they can get it from us and save time and cost without compromising on quality.” The CDI Spark 4835 installed at Ganga Stereos has a maximum plate size of 48 x 35 inches and comes with 25 optics.
Speaking about the DuPont Cyrel 1000P solvent processor, Kumar said, “The unit is easy to maintain, simple to operate and cheap to run. High dot resolution, excellent line definition, deep reverses and clean floor are achieved to meet the highest flexo standard irrespective of whether thick, thin, narrow or large plates are being processed.” The DuPont Cyrel 1000P is capable of processing photopolymer plates up to a nominal format of 36 x 48 inches and uses an innovative washout concept consisting of 6 flat brushes that transverse to each other, and contra-rotating round brushes wash out the non-polymerized parts of the plate.
