Roorkee-based Osho Flexibles hosted an Open House on 7 and 8 February 2019, extending invitations to various suppliers, manufacturers, brand owners, and even competitors to explore its new plant and witness state-of-the-art equipment in action on the factory floor.
Sagar Mehta, director of Osho Flexibles, said, “It is such a privilege for us to be able to demonstrate our passion and innovation to people who can really benefit from it.” The company has made substantial investments in its new flexible packaging plant, which commenced commercial production a few months ago.
Among the extensive array of equipment and machines present at the plant, the two blown film lines from Rajoo Engineers and the two CI flexo presses from W&H and Carraro garnered significant attention from visitors. An additional blown film line from Rajoo was in the process of installation during the visit to the plant. The Open House participants were treated to live demonstrations of various other machines installed at the facility, including center-seal pouch making machines from XL Plastics, the Simplex SL solvent-less laminator from Nordmeccanica, and print inspection machines. Notably, the new plant is also equipped with a recycling plant from Ofru.
Mehta revealed that the company has ambitious plans to print 2,000 tonnes of films monthly using the two CI flexo machines. The primary focus for these machines will be on customers in segments such as edible oil, bread, milk, diapers, and sanitary napkins. Additionally, the company has conducted intriguing experiments at its plant, including the utilization of printed monolayer for packaging atta (wheat).
Miraflex A from W&H
The Miraflex A at Osho Flexibles, an 8-color 1.3 meters wide CI flexo press, stands out as one of the most advanced in the world, operating at speeds of up to 400 meters per minute. Mehta emphasized its remarkable features, stating, “The press has a lot of features which will help us achieve outstanding performance and also create huge opportunities with a lot of perennial savings. The complete automation system in the press is integrated on a single panel. This creates a huge convenience, and you can manage the quality much better.”
Anuj Sahni of W&H said, “The Miraflex A CI flexo comes loaded with many automation features. For example, the 100% web inspection system on this press is delivered and made by us and fully integrated inside the automation panel. So it helps operator handle it with a lot of ease. In addition, we have a lot of many other features which help you on saving resources. For example, the wash-up system of the press consumes much less solvent as compared to any other presses. Then, we have systems for fast changeovers, hence reducing the downtime of the press.”
Sahni mentioned that the installation of another CI flexo press is currently underway at a company in North India. Recently, W&H has successfully installed its machines in various companies, including Vijay Neha Polymers in Hyderabad, Balaji Multiflex in Rajkot, Global Polybags in Madurai, and Jayshree Propack in Ahmedabad.
Cyberflex 1708-850 from Carraro
Osho’s Open House provided attendees with a glimpse of the latest offerings in the Indian market. Notably, the Cyberflex 1708-850 at Osho Flexibles represents Carraro’s inaugural CI flexo press in India. This 1.3-meter-wide press, installed and sold by Manugraph, boasts the capability to operate at speeds up to 350 meters per minute. It is noteworthy that the machine is imported directly from Italy.
It may be recalled that Manugraph established a strategic alliance with Carraro, based in Italy, last year. This partnership aimed to initiate the production of Carraro CI flexo presses in India at Manugraph’s advanced manufacturing facility in Kolhapur. The central aspect of this collaboration involves Carraro transferring technology to facilitate the construction of high-quality CI flexo presses in India. Following the formation of this alliance, Manugraph now delivers CI flexo presses to customers, manufactured both in India and Italy.
Pouch-making machine by XL Plastics
Attendees were also able to see live demonstrations of XL Plastics’ center seal pouch-making machine. Mehta said, “This machine is specifically designed for LDPE and recyclable materials, allowing the production of poly-to-poly pouches. The resulting pouches exhibit remarkable strength and successfully pass drop tests. Operating at a rate of approximately 120 pouches per minute, the machine provides efficient performance.”
Mira Vora of XL Plastics said, “The numerous advantages of poly-to-poly pouches. Firstly, they are cost-effective as they do not involve the use of polyester. Secondly, poly is slightly stretchable, ensuring that it remains flexible and does not become rigid or crack like polyester. Lastly, poly-to-poly pouches are entirely recyclable, contributing to environmental sustainability.”
Blown film lines
To maintain precise cost management and secure direct access to the required films, Osho has implemented its own film production. The company has incorporated both 3-layer and 7-layer blown film lines from Rajoo Engineers. The 3-layer line has a substantial production capacity of 600 kilograms of film per hour, while the 7-layer line can produce 350 kilograms of film an hour. Additionally, there is an ongoing installation of another 3-layer line with a production capacity of approximately 275 kilograms per hour. Commercial production on this third line is imminent, pending approval to initiate the power connection.
Mehta highlighted the comprehensive capabilities of these machines, describing them as fully equipped with advanced automation features. These include gravimetric blending dosing and thickness control systems. However, what sets these machines apart is their exceptional die technology, particularly noted for its excellent gauge variation. Additionally, to ensure uninterrupted operation, all blown film lines are supported by power backup systems, specifically UPS (Uninterruptible Power Supply) systems.
Sunil Jain, president Rajoo Engineers, added, “Both machines currently operational at Osho are dedicated to producing PE films. However, a 7-layer machine is particularly suitable for manufacturing barrier films that incorporate materials like nylon or EVOH, specifically for edible oil packaging. The industry is witnessing an increasing trend of film manufacturers transitioning towards barrier packaging, signaling the future direction. While 3-layer machines remain popular due to their flexibility, there’s a notable shift towards 5-layer machines. The same film produced on a 5-layer machine offers significant advantages in terms of material efficiency and improved properties.”
Recently, Rajoo Engineers completed a sale of a 3-layer blown film line to Constantia Creative Polypack in Pondicherry.
