During the Cosmohome Tech Expo 2023 held at Pragati Maidan, New Delhi from 19 to 21 July 2023, UFlex presented an impressive array of innovative and sustainable packaging solutions for beauty and cosmetics brands. The company highlighted its cutting-edge products, including the popular eco-friendly tube series – Remika, Kraftika, and Earthika. Alongside, UFlex also showcased various anti-counterfeit, brand enhancement, and other packaging solutions at the event.
Speaking about UFlex FlexiTubes at Cosmohome Tech Expo 2023, Venkatesh Rajagopalan, business head, Tube Division, UFlex, said, “The unique features of our tubes are noteworthy. Unlike traditional tubes from manufacturers in India or globally, which are predominantly white tubes with simple printing, our shelves are a striking array of brilliantly colored and intricately decorated tubes. We pride ourselves in offering a wide selection of tubes that cater to various branding preferences.”
Rotogravure reverse printing
UFlex’s ability to achieve such a high level of uniqueness in its tube solutions is primarily attributed to its specialized production process. “We take pride in being the sole tube producer in the world that follows this distinct approach. Our expertise and specialization lie in design and enhancement, which stems from our unparalleled technical proficiency in flexible packaging. We exclusively utilize rotogravure reverse printing for all our tubes, making it a remarkable and unparalleled product in the industry. This particular printing technique, followed by a combination of lamination and extrusion processes, sets us apart and enables us to offer our customers a wide range of options that are truly one-of-a-kind,” said Rajagopalan.
Indeed, being the only company in the world using rotogravure reverse printing with printing also on side seam tubes gives UFlex a significant advantage of providing tubes with 360-degree printing. This unique approach allows it to cater to any brand’s specific design needs effectively. By printing first and then laminating, UFlex can offer something truly distinct compared to other players in the industry who produce commoditized laminate first and then surface print on top of it.
The disadvantage of surface printing lies in the limitation it imposes on tube formation where printing inks cannot be present on the side seam. This can create challenges due to the constraints of tubing technology. “However, our method overcomes this issue by placing the inks underneath the laminate, enabling us to have a 360-degree ink coverage on the tube’s surface. As a result, we can seamlessly decorate tubes with inks on the side seal, crimp area, and up to the shoulder without any complications,” said Rajagopalan.
Holography as a theme
“In addition to offering exceptional barrier properties comparable to or even better than others in the industry, we have a unique offering that sets us apart. Between the barrier layer and the decorative printing layer, we provide an additional design film layer, which includes metallization and/or holography. This innovative feature adds a touch of sophistication and elegance to the tubes,” he added.
Holography, in particular, is a popular choice, and approximately 60 to 65% of the tubes produced by UFlex feature holography as a theme. The holographic effect serves two significant purposes. Firstly, it enhances the overall aesthetics of the tube, giving the brand a premium and luxurious appearance. Secondly, holography serves as an anti-counterfeiting measure for products that face significant challenges from fake manufacturers. By incorporating holographic elements into the design, UFlex provides an added layer of security and authenticity verification for customers and brand owners.
“With these unique selling points, we have established a strong foothold in the very high-end cosmetic segment. Our ability to combine top-notch barrier properties with striking holographic designs has made us stand out in the industry, ensuring we stay ahead of the competition. Brands that seek premium packaging solutions with anti-counterfeiting features find our offerings highly appealing, making us a preferred choice in the market,” said Rajagopalan.
Leading pharma brand – a success story
“Our success story with a leading global pharma brand is truly remarkable and a testament to the value of our packaging solutions. When this brand approached us, they faced a significant problem with counterfeiting and were using aluminum tubes at the time. Counterfeiting not only impacted their reputation but also posed risks to their customers who unknowingly bought fake products,” said Rajagopalan.
In response to the brand’s unique challenge, UFlex provided them with a solution that incorporated holography and a holographic strip near the side seam on the tubes. This strategic implementation made their brand instantly recognizable as the original, setting it apart from counterfeit products. The holographic features served as powerful anti-counterfeiting measures, assuring customers that any tube without the holographic elements was not genuine.
The impact of UFlex’s packaging solution was substantial. Since switching to UFlex tubes, this leading pharma brand witnessed a complete resolution of its counterfeiting issue. Counterfeiters were no longer able to deceive customers, and the authentic brand was clearly distinguishable in the market. As a result, the brand experienced significant growth of approximately 25 to 30%.
“This success story exemplifies how innovative and effective packaging solutions can not only address specific challenges but also contribute to brand growth and success. Our ability to understand and cater to the unique needs of our clients, like this global pharma brand, reinforces our position as a leading provider of high-end cosmetic packaging solutions,” said Rajagopalan.
Sustainability – three solutions by UFlex Tube Division
“In the past 2-3 years, the industry has been buzzing with the concept of sustainability, and it has become a significant demand from various sectors. We have dedicated a lot of effort to address sustainability concerns and have come up with three solutions for this purpose,” said Rajagopalan.
“We have made substantial progress in terms of reduction. Our key achievement is the introduction of a new product – the paper tube. By incorporating a paper layer into the tube design, we have successfully reduced the amount of plastic used. Currently, our paper tubes allow for a remarkable 45 to 50% reduction in plastic components. These tubes are already being used for cosmetics, and there’s potential for them to be utilized in other applications like toothpaste in the future,” he said.
The second sustainability solution involves the development of a recyclable tube. “When discussing recyclable tubes, the industry often focuses on using a mono polymer family for making its laminate. We have managed to create specialized films and an entire laminate structure based on a mono polymer. What sets our recyclable tube apart is the use of a top layer made from a highly specialized and premium product called MDO polyethylene,” said Rajagopalan.
In India, only a few manufacturers possess the capability to produce MDO polyethylene. “It allows us to reduce the thickness of the material while maintaining the same level of resilience and texture, providing an adequate ‘bounce back’ feel. The tube becomes slightly more rigid, enhancing its overall quality and user experience. This innovation brings us closer to achieving a sustainable packaging solution that not only benefits the environment but also maintains the desired product attributes,” said Rajagopalan.
Rajagopalan explained another significant advantage of MDO Poly, which is its exceptional clarity. Unlike the regular blown film polyethylene prevalent in the industry, MDO Poly has very little haze value when reverse printed. “This exceptional clarity enables us to continue promoting reverse printing techniques while maintaining high visibility and visual appeal,” he said. “Another crucial aspect of MOD Poly is its compatibility with existing laminate structures. It seamlessly integrates with other polyethylene layers, and when necessary, it can incorporate barrier properties to create a complete family of recyclable laminates. This compatibility ensures that we can produce sustainable packaging solutions without compromising on performance or functionality.”
UFlex’s third sustainability solution is a biodegradable tube. “By providing biodegradable tubes, we are actively contributing to the reduction of plastic waste and promoting a more eco-friendly approach to packaging.
“Our approach involves incorporating proprietary and confidential enzymes into the manufacturing process, viz each individual layer of film in the tube structure as well as the cap and shoulder. These enzymes enable polymer-eating microbes to latch onto the substrate when the used tube packing material comes in contact with the soil. These microbes gradually biodegrade the packing material within a reasonable time frame depending on the geographical conditions of the soil. Certification of our biodegradable solution is under process with various competent authorities, both in India and globally. This biodegradable tube solution offers an interim answer until India is fully prepared to effectively recycle plastic waste,” concluded Rajagopalan.
