Product of the month: Rotatek Universal 850 Offset

The Rotatek Universal 850 Offset is an offset print tower designed for high-performance print. Featuring sleeve technology, it is engineered for the production of pharma leaflets, folding cartons, and flexible packaging. Ranesh Bajaj of Vinsak India tells Rahul Kumar.

What does the machine do?
The Universal 850 is a rotary press that combines offset and flexo sleeve technologies, delivering print quality on a wide range of substrates. It’s ideal for markets such as pharma inserts, shrink sleeves, flexible packaging, folding cartons, and in-mould labels.

The Universal features Rotatek’s patented system of interchangeable light offset sleeves, offering unmatched ease and efficiency when changing formats. With this sleeve technology, changing jobs is as simple as removing the sleeves, eliminating the risk of material breakage.

In addition to its offset print quality, the Universal 850 stands out for its format flexibility and quick job changes. Also, it offers a cost advantage, as offset plates are more affordable than flexo plates or rotogravure rollers, reducing origination costs.

What are the different models?
The Universal range comes in three different models — U520, U680 and U850.

How do these models differ?
The Universal 520/ 680 are same except the print width, while U850 is a new and improved version, with features including wider press with 850-mm print width; new sleeves design, which are easier to install; completely new offset printing roller set, which incorporates a fourth roller to better adjust the ink to the print; new dampening design — simpler and effective design adapted to work at higher speeds; fully adjustable oscillating ink rollers system for perfect adjustment for all kind of inks and higher precision on transversal register, due to an improved design.

Is there anything in the machine which is available as a standalone, if the machine is modular?
The machine is modular, allowing the customer to select the ideal combination of printing and finishing units for their specific application. Since it’s a shaftless press, any component can be added at a later stage, offering maximum flexibility.

When was the equipment launched?
The Universal range was introduced globally in 2008 and the improved Universal 850 was introduced in 2024.

What was the thought process when the machine was conceived?
The idea was to make short-run printing of flexible packaging cost-effective without sacrificing print quality. The system offers the benefits of quick changeovers and low-cost print sleeves, while maintaining the high-quality standards of offset printing.

What are the target markets?
In pharmaceutical package inserts, formats up to 1,000-mm in length are often required. With a maximum format repeat of 1,016-mm, the Universal stands out as a game-changer in this segment.

Additionally, for in-mould labels (for example, paint bucket labels that are approximately 1-m in size), the Universal offers a significant advantage, making it an ideal choice for such applications. Moreover, the Universal is suited for the flexibles and packaging industries, offering versatility and efficiency.

What kind of substrate can it handle?
The machine can handle unsupported films from 12 microns, BOPP, PET, PVC shrink film, self-adhesive paper, paper and mono cartons up to 400-gsm.

What is the speed of the machine?
Up to 400-m/min roll-to-roll and 300-m/min roll-to-sheets.

What is the USP of the machine?
Not only is it faster and more efficient, it’s also a cost-effective solution for printing in various formats. With this technology, you only need to change two light sleeves, making the process simpler and less expensive.

Sleeve technology, which has been a major advancement in flexo printing, is now making its mark in the world of offset printing as well. The offset units come with patented bearer technology ensuring high speed printing on thin films.

Describe how the machine is user-friendly.
Each offset printing unit is equipped with 21 servo drives, making all settings and pressures servo-controlled. This ensures fully automatic size change adjustments and exceptional repeatability, delivering consistently high-quality printing.

Improved sleeve insertion and extraction system, thanks to a new design of sleeve trolley and pneumatic insertion system, which allows the sleeves to be moved without great physical effort.
Implementation of a new automatic sleeve washing system, facilitating maintenance.

What training and support are on offer?
Rotatek and Vinsak offer support and training both onsite and remotely. With over 1,800 presses installed across five continents, the team in India prioritises helping customers minimise downtime.

Vinsak encourages printer-converters  to contact the Rotatek service team for any issues. The team is committed to resolving most problems within 24 hours by providing telephonic support, remote assistance, and in-person visit.

How much does it cost?
Each machine is tailor-made, so pricing is based on the specific requirements of the customer.

User numbers worldwide?  
Rotatek has sold over 1,800 machines throughout its history. Since its launch in 2008, Universal range has sold more than 20 machines, and with the new and improved Universal 850, we expect to sell eight machines this year.