We recently had the opportunity to catch up with Arun Pandey, director of Afflatus Gravures in Noida, to discuss the company’s latest advancements in gravure and flexo printing — particularly in water-based printing on flexible substrates.
Pandey described the past year as a remarkable period for developments in both the rotogravure and flexographic segments, with significant achievements. One of the company’s successes has been the introduction and successful implementation of ITR sleeves, a breakthrough that has been well received by flexible packaging converters for seamless flexo printing.
Arun Pandey, managing director of Afflatus with a polymer flexo sleeve produced at the new Greater Noida project using DuPont ITR technology.Photo- PSA
The advanced photo polymer sleeves are manufactured completely in-house at its new state of the art facility using DuPont technology. These precision-engineered In-The-Round (ITR) sleeves have already demonstrated their effectiveness in the CI flexo presses, providing high-quality flexible packaging solutions to four plants in India. Pandey revealed the company’s ambitious expansion roadmap to introduce these advanced sleeves in several more plants in the upcoming financial year, strengthening its presence in both the Indian and international markets.
According to him the future of packaging printing relies on the seamless integration of gravure and flexographic processes, while ensuring consistent quality and outcomes. Achieving this goal will require not only technical expertise but also the creation of clear process guidelines that work effectively within a larger, interconnected production ecosystem.
Establishing the water-based gravure ecosystem
Our discussion at Afflatus focused on the implementation of water-based gravure printing for flexible packaging. This innovation has been explored, debated, and tested by various converters over the past few years. The roponents of water-based gravure printing suggest that switching from solvent-based printing requires the use of standardized press and curing systems, modifying the gravure cylinder cell structures, and maintaining precise control over the water-to-ink ratio to achieve optimal results.
Pandey shares this perspective, noting that all the major global ink manufacturers in India are making significant strides in collaboration with flexible packaging printers to develop and supply high-quality water-based inks. Afflatus has utilized its robotic laser cylinder-making and engraving systems to create a new shallow-depth flat-bottom cell structure. This innovation improves the performance of high-resolution, high-density pigments, allowing for more efficient evacuation and transfer to the substrate. As a result, the pigmentation is stronger with minimal dilution, leading to exceptional print quality while maintaining consistent dwell times at the point of contact and transfer.
Magnified details of flexible packaging using Afflatus’ laser engraved cylinders printed with water-based inks.Additionally, by reducing the water content in the ink, curing can be efficiently carried out on existing gravure presses without the need for higher oven temperatures or slower curing speeds. These advancements have been successfully implemented in several gravure plants across India and have received strong acceptance from converters and brand owners.
Pandey emphasizes that creating a reliable water-based gravure printing ecosystem requires strict adherence to precise guidelines governing all controllable variables, such as press settings, cylinder specifications, and ink formulation. Each component must operate in perfect harmony to achieve consistent and high-quality results.
He explains that a crucial aspect of this process is ensuring that inks are diluted to the correct ratio before being introduced to the press. To maintain consistency, these pre-mixed inks should be supplied in a manner that minimizes alterations during the printing process. This approach promotes a standardized workflow, reducing inconsistencies and ensuring optimal ink transfer, curing efficiency, and print quality. These measures allow converters to achieve a more predictable, efficient, and high-performance gravure printing process.
In addition, its research and development collaboration with IIT Roorkee in the past year, Afflatus has has helped define the precise conditions and parameters required for successful water-based gravure printing, forming a comprehensive ecosystem of technical guidelines. These guidelines have not only been published and patented in India but have also gained industry recognition, with one of the leading ink manufacturers licensing the patent for producing water-based inks.
Afflatus’s robotic laser engraving system has played a crucial role in advancing water-based gravure printing in India. “With this technology, cell shapes can be digitally edited, allowing for the creation of customized cylinders for various printing and coating applications,” notes Pandey.
Unlike conventional engraving, which is limited to three fixed angles, laser engraving offers greater flexibility. This technology enables the production of cylinders with optical resolutions of up to 400 LPI or even higher. “Cylinders can be tailored according to packaging design, ink properties, and substrate characteristics, ensuring improved print quality and efficiency,” he adds.
Pandey concludes by saying, “We foresee that the majority of gravure printing will transition to water-based technology within the next few years—it is the future of sustainable packaging in India.”
