Powering the Future of Flexible Packaging Printing with India’s First Hybrid Inline Wide Web Flexo Machine.

The Indian flexible packaging market is growing at a rapid rate of 12% to 15% every year. Today, consumers are highly brand conscious. Excellent packaging graphics are no longer optional—they are vital for product survival.

At the same time, a surge of modern startups is entering the market daily. These new businesses require multiple Stock Keeping Units (SKUs) in tiny quantities to test the market safely. They demand premium packaging but need to launch with minimal upfront investment. This shift has created an operational bottleneck for traditional converters.

To bridge this gap, industry pioneer Star Flexi Films, led by Director Ashish Savla, has joined forces with engineering trailblazer Puma Roto G, led by Director A Prasad. Together, they are introducing a game-changing solution to the converting sector.

The Conventional Printing Dilemma

For years, flexible packaging converters have been caught in a technological crossfire when managing short-run, multi-SKU orders:

The Rotogravure Hurdle

Traditional rotogravure printing delivers beautiful quality. However, it requires a massive initial investment in heavy metallic cylinders. When a brand has ten different flavor variants (SKUs) but only wants small test quantities, the cylinder setup costs make the job commercially impossible. High Minimum Order Quantities (MOQs) alienate small brands.

The Narrow Web Limitation

Narrow web presses can handle small jobs. Unfortunately, they suffer from restricted web widths. They also rely on extremely expensive UV inks and highly energy-consuming UV curing dryers. While they work fine for a startup’s very first order, they quickly become financially unviable as soon as that customer’s business grows.

The CI Flexo Gap

Central Impression (CI) flexo systems offer speed but often lack the mechanical agility to efficiently balance ultra-short runs with wide-web flexibility on diverse materials.

The Engineering Breakthrough: Puma Roto G’s Hybrid System

Recognising this industry-wide pain point, Mr A Prasad, Director of Puma Roto G, dedicated years to intense technical research and development.

The result is a crowning achievement for domestic manufacturing: India’s very first High-End Hybrid Inline Wide Web Flexo Printing Machine.

This machine harmonises the best features of rotogravure, narrow web, and CI flexo into a single powerhouse platform. It is engineered with world-class technical specifications designed to rival elite global standards:

Substantial Web Width

Supports structural widths up to an impressive 1300 mm, ensuring converters can handle wide-format commercial jobs effortlessly.

Massive Production Speed

Reaches operational run speeds of up to 350 meters per minute (mpm) without a single compromise on final dot reproduction or print crispness.

Advanced Gearless Architecture

Built as a completely gearless system, reducing mechanical wear, backlash, and costly maintenance downtime.

Fully Servo-Driven Automation

Utilises dedicated multiple servo motors on every printing station to ensure instantaneous registration, micro-precise control, and minimal setup waste.

Ink Cost Optimization

Runs smoothly using normal, affordable flexo inks instead of budget-breaking UV inks, drastically slashing running costs.

Extreme Substrate Versatility

Seamlessly processes diverse packaging materials, including delicate papers, Polyester films, BOPP, and flexible LDPE.

Empowering the Converting Market

STAR FLEXI FILMS

Under the visionary leadership of Director Ashish Savla, Star Flexi Films is the sole marketing partner for Puma Roto G’s machinery range.

Star Flexi Films is bridging the gap between innovative engineering and shop-floor reality.

✓ Accept tiny test orders from startups
✓ Scale the same jobs to high-speed production
✓ Eliminate expensive cylinders & high ink costs
✓ Boost your profit margins
✓ Give brands the creative freedom they deserve