Labels and Packaging Innovation Asia • 6 2021 -
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Digital Process adds more The recent installation of a new ThermoFlexX TFxX 48 was carried out by the Pakistani platemaking pioneer’s own engineers, supported remotely by the XSYS team. Despite restrictions due to the COVID-19 pandemic, the flexo plate imager was up and running within three days of arriving at the repro house in Karachi. Digital Process (Pvt) Ltd has led the way in digital flexo platemaking in Pakistan since its inception. Founded in 2006, the company is today the top repro house in the country, supporting many of the biggest printing companies and their global brand customers with a wide range of prepress services. Flexo plates account for 65% of sales. The 24/7 operation has 50 staff and boasts turnaround times of just 24 hours from approval of artwork, all made possible by running four production lines, employing a host of highly experienced graphic designers and utilizing strong ERP software to manage the workflow. The company also operates as a distributor of other flexo consumables including sleeves, inks, anilox cylinders, tapes, cleaning chemicals and flexible dies, and exports to the Middle East, Africa and occasionally Europe. Continuous improvement with best equipment In order to expand capacity further in the flexo platemaking department, which consumes over 10,000 sqm of photopolymer plate material each year,
Digital Process has recently invested in an additional digital imager from XSYS. The choice fell for a ThermoFlexX TFxX 48 model as a complement to an existing ThermoFlexX TFxX 60, which was installed just two years ago. This means that the company can now deliver high-quality flexo plates for the broadest range of applications, from labels and flexible packaging to corrugated boxes and displays. “Our experience with the larger ThermoFlexX 60 has been great and it was very easy to integrate into our Esko workflow. Having put a few thousands laser hours on the machine already, the technology has proven itself, and with 5080dpi, we know we can make the best quality plates, which will deliver exceptional print for our customers,” says founder and CEO Zain Fazal. He continues, “We are considered the best in flexo plates in the country, so customers expect the highest quality and great service from us. That puts extra pressure on us, but I see that as a good thing, because it means that as we are continuously improving and investing in the best equipment.”
Growth through trust and partnership The partnership with Flint Group Flexographic, which is now part of the newly established XSYS division, goes right back to the beginning. “The plates that were available in Pakistan when we first set up business were simply not good enough for what we wanted to achieve,” explains Fazal. “We knew that the demand for higher quality would grow, so we approached Flint to discuss importing their plates ourselves and they agreed.” The cooperation has been beneficial to both parties. Digital Process grew exponentially in the first three years to become the largest platemaker in the country. “Our first import order with Flint was way below their standard MOQ, but Regional Business Manager Roy Schoettle took the initiative and supported us. As a result, Flint’s market share in Pakistan also multiplied in the following years.”
