Reynders established its label printing unit in India 5 and a half year ago in the Chopanki industrial area, Bhiwadi, Rajasthan. The plant is a neat and clean facility with maximum automation and minimum manual intervention, the absence of dust makes the machines run smoothly.
Reynders India mainly serves the pharmaceutical and cosmetic industry and makes specialty products such as game labels, hanger labels, double and triple-layered labels which can contain the same information that is normally enclosed in the packaging for information about the product. In September 2009 the company had a 9-colour narrow web specially built Gallus EM 280 with special attachments for producing layered labels in line and an Omega FlyTec 500 inspection system. It also had a complete Esko workflow and digital flexo imaging system including CDI Spark for imaging both flexo plates and rotary silk screens.
The company has continued to grow and strengthen its capabilities. It subsequently added another 8-colour EM280 Gallus label press. It has a Domino inkjet system variable data printing on the back sides of pharma labels, a necessary requirement for that segment. Reynders also installed the first Convertec Braille Maker One in India which is a digital DOD inkjet system for depositing UV cured varnish for Braille characters on labels in twelve languages with Hindi about to added. The system has a nozzle block warning system and the inspection of the Braille writing on labels is carried out on the FlyTec inspection system using special software. More recently, the company added an EFI Jetrion 4830 digital colour label press which is used for initial and trial runs of labels for cosmetics and soaps. The short run digital labels are also used by marketing companies for sample making.
“Our speciality is the innovation and uniqueness of the product we make. The medical hanger labels for instance can hold the weight of the bottle for 6 to 7 days and are vigorously tested for quality to make sure that the bottle doesn’t fall off,” said Karl Vandenbussche, Director Reynders. In the double and triple layered labels, the inner layers of the label contain the information about the contents, MRP, best before date, and other user data. Then there are labels where you can peel off the upper layer and the lower layer reveals all the mandatory information. The two layers are glued to each other and the printing is done on the glued surface with UV ink. The major customers of Reynders India include Dr Reddy, Ranbaxy, Cipla, L’Oreal and several other established pharma and cosmetic brands.
With the two Gallus narrow web flexo presses Reynders has an efficient prepress section with the flexo and rotary screen digital imager. The production software works in conjunction with Reynders own ERP system called RAS. The software makes sure that the job in process has all the set parameters and allows the plate making only if all the parameters match those fed to it previously. “Reynders has a similar set up of machines throughout its plants all across the world. This makes it easier to maintain quality and it helps in trouble shooting at times when the process is uniform, no matter what location you are working at,” he added.
“The Indian market is big enough for the current capacity of the Bhiwadi plant and the next target is to grab more of the Indian territory before focusing on anywhere else. As for now, the current manufacturing capacity is not completely occupied yet and I would first like to see it filled up,” Vandenbussche further stated.