At Plastindia 2023, Rossini displayed sleeves that are 40-50% lighter than conventional ones. Introduced in November 2021, these sleeves use an extra polyurethane layer which is ultra-thin, low-density PU foam. “These sleeves are aimed at flexo converters who print larger repeats with wider widths. There is a lot of vibration and bounce in the machine. So to offset that, we came up with this high stability lighter sleeve,” said Ashvin Hebbar, sales director of Rossini India.
The company also displayed its standard products for gravure lamination, i.e. gravure sleeves, at the exhibition. However, the company’s main highlight at the exhibition was its Ecograv system. Hebbar said, “The Ecograv system is going to revolutionize rotogravure printing. The system was launched after 10 years of rigorous R&D at the K show in 2022.”
The Ecograv system replaces the copper and chrome cladding with a special polyurethane-based technopolymer that has passed all the tests of quality and machinability on industrial lines and can be engraved electromechanically. The system is now a key focus of Rossini “because that’s where we feel rotogravure can be made sustainable,” said Hebbar. The system not only responds to the need to replace the hexavalent chromium, shortly to be banned but also an alternative to a high pollutant production system that is also expensive to manage at various levels, not least that of the healthiness of the working environment and the disposal of toxic substances used in traditional processing. “So I think Ecograv is the right answer to make rotogravure printing become sustainable and environmentally friendly – not just in terms of the material used but also for the production process of the cylinder coating.”
Chromium trioxide ban
Chromium trioxide, which is also known as hexavalent chrome, is a major electrolyte for the chrome plating of gravure cylinders. As an electrolyte, it is toxic but as metallic chrome, it is not poisonous. These uses add a protective coating to metal parts and products and enhance the strength of the surface as well as wear and corrosion resistance. The treated surface does not contain chromium trioxide. Chrome plating and surface treatment are done in industrial settings, exposing workers to harmful chemicals that can cause cancer.
The European Chemicals Agency (ECHA) lists chromium trioxide in REACH Annex 14, and the default position is therefore that its use is prohibited unless authorization has been granted. Currently, gravure printing is covered by a so-called upstream authorization issued to the CTAC consortium. The European Commission granted authorization for five uses of chromium trioxide in December 2020, including functional chrome plating and surface treatment. The current authorizations expire in September 2024, but authorization holders can re-apply by submitting a review report to ECHA by March 2023.
New plant
“This year we are planning to have our own manufacturing unit In India for steel base which is required in sleeves. Currently, we only produce rubber coverings and rubber rollers in India while steel base is imported from outside. So the plan is to have an in-house manufacturing unit for the steel base. With the in-house plant, we will have complete control over the production of the steel base and the rubber, which is one aspect of the investment. The second aspect is to bring down the lead time for the steel base which is very high currently.”
Consolidation
Speaking about the industry, Hebbar said, “The flexible packaging industry is growing in double digits and India is going to see consolidations. I think it’s time for consolidation – and it’s already happening. And when you see big non-packaging multinationals investing in packaging and converting industries, and also buying out these companies, the indication is clear that the industry is moving in the right direction.”