Libako Packaging, a print and packaging specialist based in Kolkata, has boosted its production efficiency by installing its first narrow-web flexo press – a Gallus ECS 340 flexographic press with UV application, in-line foiling, lamination, and die-cutting units.

For a long time, Balai Adhikary, director at Libako Packaging, had a keen interest in labels and convertible packaging solutions. When he and his team visited drupa in 2016, he envisioned the immense potential that flexo printing and labeling could offer. The company made a bold move during the pandemic 2020 by investing in the Gallus ECS 340 narrow-web flexo press.

Adhikary said, “We prefer to invest in proven technology along with innovation, brand value, versatility. We examined all the presses and their configuration, where Gallus flexo press stood out as the leader for us. We were awestruck by the print quality, registration with minimal wastage, and the support from Heidelberg India’s service team.”

Adhikary added that process flexibility of the press and its ease of use were among the other highlights of Gallus ECS 340, which helped seal the decision. The Heidelberg India team did a fantastic job of installing the press in just six days after the machine arrived at the company site during the second wave of the pandemic.

“The Overall Equipment Efficiency (OEE) of the press is defined by various factors, including available time, quality, machine production speed, as it is the mantra towards the success of label converter. The equipment automation in Gallus ECS 340 ensures the highest level of OEE to us. The dedicated service and print application support from Heidelberg and Gallus team helped us reduce material waste and time loss in production and job changeovers, resulting in high productivity. These are some of the driving factors to be with Heidelberg and Gallus family,” said Adhikary.

“Along with the Gallus ECS 340, we have added a high-speed slitter and inspection, offline hot foiling, and flatbed die punching machine with a conveyor. We also have offline screen-printing machine and coaters,” added Adhikary.

Gallus ECS 340

The Gallus ECS 340 press comes with a technical core granite base which eliminates the vibration during printing operation. The modular design and low carbon footprint ensure minimal space requirement. The shortest web path reduces the production waste. The quick process change over on the primary level of the press provides maximum available time in production and OEE levels. The automation feature includes easy job setup, pre-register job data storage and recall, format length correction, easy and special design of chamber doctor blades, and changeover. The large diameter of the chill impression cylinder keeps the material physical properties constant through the print process for accurate print reproduction, even on repeat job orders. Integrated direct servo drive shaftless and gearless press ensures high substrate flexibility with Gallus ECS 340.

Process flexibility and modular structure are key drivers in today’s world, and Gallus ECS 340 can be extended with add-on processes as required at any point in time. The Gallus 340 comes with specially designed lightweight aluminum printing cylinder sleeves that ensure high printing quality, consistent reproducibility, and maximum aging stability throughout their entire service life.

Libako’s journey so far

Libako Packaging started as a label screen printer in 1981 with a vision to provide quality print solutions to its clients. It saw a great opportunity and potential in the print and packaging industry with printing labels for footwear and cotton garment manufacturers in Kolkata, by using screen-printing. Within few years, Libako Packaging diversified its portfolio to include offset, commercial printing, packaging, POS, wood, metal, and plastic fabrication.

The company has two plants – one in Matheswartala road, spread across 45,000 sq. ft, dedicated to offset, digital, and large format printing, pre-press, and post-press, along with other fabrication machinery. The second plant is a newly constructed 9,000 sq. ft eco-space, one-stop solution provider for premium quality products output located at Jalpath, Kolkata.

Ankan Adhikary, the next-gen entrepreneur who joined his father’s business, is involved in day-to-day operations. He added, “We want to diversify into a complete packaging solution provider with comprehensive service offerings. We are concerned about the environment, and hence, we have set up our new factory adhering to all eco-friendly norms at Jalpath. We want to grow as an environmentally responsible company with versatility, quality, and innovation.”

Awards and accolades

Libako Packaging and The Ad-O-Graphy (sister concern of Libako) achieved a perfect 100 on L’Oreal Paris’s social audit in 2018. Today, the company obtains the SEDEX SMETA 6.1 (4 Pillar), GMP, and FSC certifications. Its clients are well-known companies from the FMCG, white goods, cosmetic, garment, and paint industries.