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Total Print Solutions expands with Lombardi

Lombardi Synchroline 430 installed at Total Print Solution in Mumbai

Total Print Solutions, a Mumbai-based converter founded in 2008, has installed a Lombardi Synchroline 430 press to expand its production capacity. The company has also opted for a 430mm-wide Vinsak USAR slitter rewinder to complement the press.

‘With new machinery, we expect to double our labelstock consumption from the current 400,000 sqm,’ said Sandeep Zaveri, managing director of Total Print Solutions.

Installed by Vinsak, the exclusive distributor of Lombardi presses in the Indian sub-continent, the 10-color press features the first Bravo screen unit in India, as well as cold foil, delam/relam, turnbar, web cleaner, chill drums, static eliminators, three die-cutting stations, sheeter and conveyor. 

While Total Print is catering to the food and lubricant markets, the 17in wide Lombardi press will assist the company’s growth into other segments as well as enhancing its capabilities in combination printing and added-value options such as Braille, booklet labels and lamination. With increased and enhanced production capabilities, Total Print intends to increase its overseas business from the current 15 percent to 50 percent in the future. It currently exports to the Middle East and Africa. 

‘Our focus is to expand our market reach with new capabilities, and print cartons, shrink sleeves and in-mold labels as well. We are doing many jobs with different exciting combinations. We successfully ran an 8-color job with cold foiling on Lombardi at 130m/min. The press can print up to 5-layer labels at a speed of 50m/ min when using the Bavo screen unit,’ said Zaveri. ‘The advantage of the press is that a job can be set up with defined wastage and configuration. We are pleased with this investment as it is an easy-to-operate and flexible machine that gives us a lot of scope to grow.’

Comparing the Bravo screen unit to rotary screen, Zaveri said: ‘Ink deposition is easier on a flatbed screen unit and it also enables easy changeover. Further, the screen can be made and exposed in-house at a relatively low cost and the quality remains great.’ 

Smooth installation 
Italy-based manufacturer Lombardi, deployed its engineers to train operators, while local distributor Vinsak continues to provide technical support.

Ranesh Bajaj, managing director at Vinsak, added: ‘The Vinsak team is delighted to work with Total Print Solutions. The company enabled smooth installation and training process.

While Total Print is focusing on getting maximum output from the new press, it is also utilizing its synergies for future expansion. The company has invested in a plot of land in Chakand MIDC Pune, a fast-developing industrial area close to Mumbai, for future growth. 

‘We continuously study the market. We are looking at another press with digital capabilities for the next phase of expansion in Pune, hopefully within the next two years,’ informs Zaveri. 

Gearing up for growth, Total Print has deployed an ERP system that has integrated all its departments and helped to improve efficiencies at the factory. ‘Now, we record each step of the job from the time it comes to the plant to dispatch. This has enabled us to gauge loop holes in our working environment that were causing delays and thus has improved our efficiency by 50 percent,’ says Zaveri. 

With an eye on environmental sustainability, the company uses FSC-certified labelstock. ‘It is a good beginning to help the environment and be sustainable. Although it is tedious to get the certification, they ensure that we get in the habit of following its required norms. It is also important from the brands’ point of view. Global brand Ikea, for instance, has made it mandatory to use FSC-certified labelstock for its labels,’ says Zaveri. 

Total Print is also working towards recycling its matrix waste efficiently to reduce its impact on the environment. ‘We are working towards wastage being converted to electricity. All matrix waste including facestock, adhesive and silicone liner can be converted to another energy form efficiently. The only requirement is to separate the film and paper matrix. In partnership with another company, we are working on this recycling method because we believe this is truly the need of the hour,’ Zaveri explains. 

ABOUT THE AUTHOR

Aakriti Agarwal is India and Southeast Asia editor for Labels & Labeling.

Aakriti has been India editor for a number of years, and editor of the online newsletter, Label News India.

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