Innovative solution addresses joint line challenges and improves printing consistency.
The flexographic printing industry is witnessing a major transformation with increasing demand for higher productivity, better print quality, and consistent output. Addressing one of the key challenges in flexo printing — the joint line issue in sleeves — PAL Printech has introduced advanced jointless sleeve technology for flexible packaging, narrow web, and coating applications.
In an interaction, Ritul Zaveri, PAL Printech, shared insights into the company’s technology, development journey, customer response, and future growth plans.
A New Venture Focused on Advanced Flexo Solutions
PAL Printech is a new initiative formed by combining the expertise of Pinmark Block LLP, Arvind Rubber, and Line-O-Matic to develop innovative solutions for the printing and packaging industry.
The company specialises in manufacturing jointless sleeves suitable for different substrates, including plastic films, paper, and other flexible packaging materials. Along with sleeves, PAL Printech also provides specialised elastomer plates for coating applications such as high-gloss coatings and release coatings.
“We have been working on this technology for more than eight years, and now we are introducing it to the wider market.”
The technology enables converters to achieve seamless printing performance while improving efficiency and consistency.
Solving the Joint Line Challenge in Flexo Printing
With many converters shifting from gravure to flexographic printing, eliminating the joint line issue has become a major requirement. Joint marks can affect print quality, especially in long-run jobs where consistency is critical.
“When converting from gravure to flexo, the biggest challenge is avoiding the joint line. With our solution, we eliminate the joint line completely and provide an additional value-added solution for flexographic printing.”
— Ritul Zaveri, PAL Printech
According to Zaveri, the jointless sleeve technology reduces the dependency on tapes and specialised mounting processes.
“With this solution, there is no requirement for tapes or additional mounting expertise. Mounting errors are reduced, and the process becomes much simpler. It provides a direct imaging solution with no tolerance issues,” he explained.
The key advantages of the technology include seamless printing, improved registration accuracy, reduced mounting errors, faster job preparation, and consistent print quality.
Wide Range of Applications
PAL Printech’s solutions are designed for multiple industries, including flexible packaging, paper cups and straws, notebook printing, textile packaging, hygiene applications such as diaper film printing, and selected narrow web applications.
While jointless sleeves are mainly used in flexible packaging, the company is also exploring opportunities in the narrow web segment.
“In labels, sleeves may not be required for every application, but there are certain jobs where jointless sleeves can provide significant benefits,” said Zaveri.
Long Journey of Technology Development
Although PAL Printech was established in 2017, the development journey behind the technology started much earlier.
“I was looking at this product concept since 2004 when I entered the industry. I was interested in developing it, but at that time we did not have the required raw material support and technology availability,” explained Zaveri.
After years of research and development, the company received support from technology partners, including Böttcher and Ligum, which helped establish the manufacturing process.
Positive Customer Response
According to Zaveri, customers who have adopted the technology have shown strong satisfaction and are gradually increasing its usage.
“Those who are using it are very happy and are adding more jobs with this solution. They are gradually moving towards this technology,” he said.
One important application area is tobacco packaging, where consistency and joint-free printing are highly critical.
“One of our customers in tobacco packaging had continuous joint-related issues. After adopting our solution, they converted their complete range into this combination of sleeve and flexographic plate registration, resulting in improved printing performance.”
The company has also developed a combination of sleeve and flexographic plate registration to achieve better stability and accuracy during printing.
Expanding Market Awareness
While PAL Printech has been working with selected customers in the paper segment, the company has recently increased its focus on flexible packaging applications.
“This is our first exhibition focused on the flexible packaging industry, and the response has been very encouraging,” said Zaveri.
The company is strengthening its market presence through exhibitions, customer interactions, and direct engagement.
Global Technology with Indian Focus
Jointless sleeve technology is already established in international markets, especially in Europe. PAL Printech aims to bring greater awareness and adoption of this technology in India.
“This is an advanced flexo technology where direct laser engraved elastomer sleeves can be integrated. It is already being used internationally, and now we are creating awareness in India.”
However, Zaveri clarified that the technology is not intended to replace conventional flexographic printing.
“It will not replace flexo. It will work together with flexo as a supportive technology to improve performance.”
Strong Export Focus
PAL Printech follows an export-oriented business model, with approximately 70% of sales coming from exports and the remaining from the domestic market.
The company supplies solutions to markets including Africa, the Middle East, Europe, and other international regions.
Apart from printing sleeves, PAL Printech also offers specialised plates for coating applications, including high-gloss coatings and embossing requirements.
Supporting the Future of Flexographic Printing
With increasing demand for efficiency, automation, and consistent print quality, PAL Printech’s jointless sleeve technology offers converters a practical solution to improve productivity and enhance flexographic printing performance.
“It is not a replacement technology, but a value-added solution that helps printers achieve better results with flexo.”
Through continuous innovation and market development, PAL Printech aims to support printers and converters in achieving higher quality, improved efficiency, and greater competitiveness in the evolving packaging industry.
