Strategic shifts in 2024 guide innovations through sustainability in 2025 (Part I) — The Noel D’Cunha Sunday Column

Acme Rolltec’s Sandeep Sharma: Innovation with anilox

Acme Rolltech has introduced a range of new engravings designed to meet the evolving needs of narrow and wide web printing. Among the standout innovations in 2024 was ATAC, an anilox for screen-type raised effects, and AHDW, developed for high-opacity white printing. The company also launched AGLIT for heavy glitter varnish transfer, s2.0, an advanced version of its high-density white anilox.

Acme Rolltech made significant strides in expanding its global presence in 2024, now exporting to over 30 countries with established agent partnerships in 13 markets. The company’s strong performance was marked by continued product innovation and the booking of its third laser engraving machine at Drupa 2024, set for installation in March 2025. In anticipation of growing demand, Acme Rolltech has also embarked on a major expansion, constructing the third phase of its plant along with an in-house fabrication unit capable of producing over 1,000 rolls per month. This new facility, expected to be operational by the second quarter of 2025, underscores the company’s commitment to scaling up production and enhancing delivery timelines.

The launch of the ACE – Advanced Channel Engraving system in 2024 provided further advantages in ink transfer and consistency, reinforcing the company’s reputation as a leader in anilox innovation.

Looking ahead to 2025, embellishment will continue to be a dominant trend in the printing and packaging sector. Acme Rolltech is well-prepared to capitalise on this demand, with plans to launch its ASC – Acme Super Cell engraving technology at PrintPack 2025. This new development is expected to provide substantial advantages in achieving higher speeds and improved ink laydown, aligning with the evolving requirements of modern printing machines. The company also aims to increase anilox sales by 30% compared to 2024, further expanding its market share and strengthening customer relationships globally.

APL Machinery’s CP Paul: More automation

In 2024, APL Machinery responded by introducing the first and only made-in-India seven-colour digital label press–designed specifically for label and flexible packaging applications. The company also expanded its portfolio in embellishment technology, launching India’s first fully automatic screen printing with foiling, offering capabilities such as 3D foil, cold foil, cast and cure, and spot UV.

At Drupa 2024, APL Machinery introduced its seventh-generation LED-UV curing systems. This innovation significantly reduces energy consumption while providing an extended lifespan, making it both cost-effective and sustainable.

In 2024, APL Machinery strengthened its footprint both in India and internationally. The company achieved significant milestones with installations in Spain, Germany, Algeria, the UK, and Sri Lanka.

APL Machinery plans to launch several advanced products in 2025, including single-pass digital printing solutions and innovations for flexible packaging. The company’s upcoming machines will integrate energy-efficient technologies, promote the use of eco-friendly materials, and minimise waste. The company is introducing features to optimise energy consumption, reduce material waste, and enhance recyclability, enabling businesses to lower their carbon footprint while improving efficiency.

Autoprint’s CN Ashok: Strategic course for 2025

2024 saw rising demand for high-visual and tactile effects in folding cartons, prompting Autoprint to refine its machinery for superior texture and finish. Stricter quality standards drove the development of advanced inspection systems, while a shift towards offline solutions led to machines offering greater flexibility and product diversity.

Drupa 2024 proved pivotal, with Autoprint’s flagship machines gaining traction in Spain, Chile, the UAE, and beyond. CN Ashok, managing director, Autoprint, “The fact that both developed and emerging markets have embraced the same Autoprint products is a strong testament to their reliability, affordability, and universal appeal. Reputed brands like Emirates Printing Press (EPP) of Dubai and JF&I partnered with us after thoroughly reviewing our machines and processes, proving the quality we deliver.”

Key 2024 launches included the B1 offline UV coater, now sold out until mid-2025, and the upgraded Drip-Off 80 with single-pass soft-touch applications for textiles. Ashok claims that the AFOSOL varnish line and Dextra 67 die-cutter have set benchmarks in cost-efficiency and precision. New Checkmate CM 30/65 inspection systems catered to pharmaceutical sectors, addressing 85% of carton sizes under 25 cm.
There was briefly a surge in orders strained supply chains. However, the company was able to counter this by expanding its workforce by 25%, investing in vertical storage and precision machinery from FFG Group.

As India’s sole provider of integrated foil stamping die-cutters, the company enhanced short-run premium product capabilities. The company is channeling resources into high-spec VMC machines and R&D to streamline manufacturing and deliver faster ROI for clients. A restructured, process-driven customer support network aims to reduce downtime by 15%, ensuring seamless operations for users of its seven core product verticals, including foil stamping machines and digital finishing equipment.

Looking ahead, Ashok anticipates offline solutions dominating growth, particularly in emerging markets seeking affordable embellishments. Autoprint anticipates robust growth across North Africa, Southeast Asia, and Latin America – regions mirroring India’s market dynamics. To meet this surge, the company has scaled its annual production capacity to 48 offline coaters, 36 inspection systems, and 24 die-cutters.

Bindwel Pallippuram Sajith: High expectations from book industry

On one side, there was overwhelming demand for high-volume, cost-efficient equipment for textbook and mass publishing, while on the other, publishers increasingly sought flexible, short-run, and on-demand solutions for boutique and specialised markets. Bindwel responded by working closely with publishers and printers to refine and adapt its offerings, re-engineering the BW@2500 perfect binder to reduce energy and adhesive consumption while minimising wastage.

The year was marked by significant milestones, with installations across major publishing houses, including Gita Press and Mittsure Publications, and a strong post-Drupa order pipeline. Our global expansion efforts saw us strengthen our presence in Africa, Southeast Asia, and the Middle East, where we are setting up service and spare parts centres to ensure long-term customer support. Bindwel also ventured into the digital post-printing space with the SigLoch XE-CÜT and initiated the local assembly of primary packaging machines in India.

Drupa 2024 was a showcase of Bindwel’s evolving approach to bookbinding and post-printing solutions. We introduced products tailored for personalisation, micro-runs, and customisation at scale. Key innovations included the Freedom 2K, which features sub-one-minute changeover for short-run production; the SigLoch Zen, designed for the B2C segment with a focus on efficiency and affordability; and the SigLoch XE-CÜT, India’s first “any shape cutter/sample maker” for digital post-printing applications.

Installation targets for 2025 reflect this growth trajectory, with a projected 15% increase in India and 20% growth in Africa, Southeast Asia, and the Middle East. Inline and nearline solutions will dominate the K12 and short-run publishing segments, and we expect to add at least 125 new customers in the digital post-printing sector. The completion of the new SigLoch plant will support increased production capacity, while investments in training and service infrastructure will enhance customer support.

Bindwel’s investments in technology, training, and customer support will further solidify its industry leadership. We are expanding our Innovation Centre to drive incremental improvements across all product lines and launching extensive training programmes to help customers maximise machine efficiency.

Arrow Digital’s Sam Patel: New milestones

The demand for sustainability and digital transformation has reshaped the market. We anticipated these changes early and introduced our ArrowJet Line to meet these evolving needs. The adoption of Nestlé-compliant water-based pigment inks aligned with regulatory requirements for food and pharmaceutical packaging, while Memjet’s DuraFlex and DuraBolt technology enhanced speed and resolution, allowing brands to achieve vibrant, customisable prints with minimal environmental impact.

In terms of installations, 2024 was a milestone year for Arrow Digital, with record installations of the ArrowJet Line in India, particularly within the food, pharmaceutical, and label printing sectors. One of the standout moments was the installation of the first ArrowJet Aqua 800M at Neha Converters in Ahmedabad, marking a pivotal step in India’s flexible packaging segment. Global expansion also continued, with significant installations across North America, Europe, and the Middle East, reinforcing the company’s growing presence in key markets.

Innovation was a central focus, with new product launches at LabelExpo and Drupa 2024. The ArrowJet UV introduced high-resolution UV printing with advanced white ink applications, while the ArrowJet Hybrid Pro M+ integrated flexo stations and inline features for premium labels and packaging.

Arrow Digital expects a 25% increase in installations in India and a 30% rise globally. To support this growth, we are expanding our production capacity, strengthening our service network, and introducing flexible financing options.

In a move to foster industry collaboration, Arrow Digital will open a new Experience and Innovation Centre in Ahmedabad. This facility will showcase the latest technologies in label and packaging, sign and graphics, and visual merchandising. Designed as a hub for creativity and exploration, it will allow customers to stay ahead of industry trends, offer hands-on testing, expert colour management guidance, and technological insights to optimise production processes.

Cosmo Films’ Kulbhushan Malik: Sustainable packaging

In 2024, the printing and packaging market saw a focus on sustainable laminates and high-speed packaging. FMCG brands upgraded to HFFS and VFFS machines, requiring specific film properties. Cosmo Films adapted by upgrading products, using in-house testing, and launching new sustainable solutions after successful machine trials. The company also focused on specialty films, reducing waste, using renewable power, and expanding its Cosmo Green Graphics product line.

Cosmo Films serves customers in over 100 countries and has become the largest exporter of BOPP films from India and the largest producer of thermal lamination films worldwide. A key milestone in 2024 was the investment of INR 10-crore to set up the PackSmart R&D facility, aimed at enhancing operational and quality efficiencies. The company reported a 25% growth in exports as a result of continuous product developments and launches.

Among the new launches in 2024 was Cosmo Green Graphics, a PVC-free film for graphics applications. The company also introduced a new range of DTP films, sustainable laminate solutions for noodles and snacks packaging, BOPP ultra-high barrier films with improved seal strength, superior barrier films for aluminium foil replacement, high-speed BOPP films for soap packaging, and PCR-based BOPP films for various applications.

Like many in the industry, Cosmo Films faced supply chain disruptions and rising production costs in 2024. Capacity constraints due to high demand led to additional production capacity expansion. Waste reduction and recycling efforts were intensified to minimise losses, while scaling up new product lines such as PET speciality films, PET-G, CPP films, and capacitor films required focussed efforts. The company also worked towards eliminating quality defects and strengthening internal processes.

To meet increasing demand, the company plans to install new coating, metallising, and lamination lines, as well as a new BOPP line at its Waluj plant in Q1 of FY25-26. Future launches will include further expansions of the Cosmo Green Graphics and DTP film lines. Cosmo Films is also working on a sustainable laminate solution for the ready-to-eat market, where BOPET-based laminates currently dominate. A three-layer BOPP-based alternative is being developed, with an expected launch in 2026.

Investments in technology, R&D, and employee development will be central to Cosmo Films’ strategy in 2025. The company has earmarked Rs 10- to Rs 20-crore to upgrade R&D facilities, with a specific focus on developing innovative niche-market products. New offline coating facilities are being installed to advance flexible packaging solutions.

The company is also strengthening internal processes through TQM initiatives to enhance quality and delivery consistency. Employee engagement and skill development remain priorities, along with IT upgrades through SAP S4 Hana to streamline business operations.

DGM Automation India’s Puneet Aggarwal: Rising demand

DGM India has seen steady growth since its entry into the Indian market in 2019. We have consistently expanded by 30-40% year on year, and 2024 has been our best-performing year so far. The company is also expanding globally, with direct operations in Europe and Vietnam. To accommodate rising demand, DGM has acquired an additional 40,000 square metres of land, with a 150,000 sq ft production facility under construction. The first phase of this project is expected to be completed by April 2025, with full completion by the end of the year.

At Drupa 2024, DGM launched several new products, including the ServoX folder gluer, which boasts a top speed of 500 metres per minute, and speed hooks designed for high-speed 4/6 corner carton production at 32,000 to 34,000 cartons per hour. The live demonstrations at Drupa showcased how these innovations enhance productivity for our customers. The company also introduced the Technocut 1200S, Technocut 1450S, Technocut 1650S, and the Technocut 1050TE dual press die-cutters, broadening its portfolio to meet increasing industry demands.

Manufacturing is gaining momentum. With more brands and startups entering the space, the demand for packaging solutions will only increase. We aim to exceed 50 installations in India and 1,200 globally.