Our Process

Since we encounter lot of variables in the printing field, we ensure all steps are undertaken to reproduce the images exactly as per the order parameters provided by the clients.

The customers’ specifications are taken and corrected using advanced graphics software. The images are digitally printed, checked, and then signed off by competent personnel. The approved images are then sent to the engraving department where there are further checks before the images are engraved on to the cylinders.

The base shells required for making the cylinders are either made of MS pipes or rolling MS Sheets into the required length and Diameter. Because of the stable steel bases, the cylinders can assume higher length and diameter. The dynamic balancing of these cylinder enables the customers to print at high speeds with minimal vibration.

After the Base Shells attain satisfactory finish, they are immersed in Nickel Bath to attain a thin layer of Nickel coating. The primary reason for nickel plating a cylinder immediately before copper plating is because Nickel plating will adhere to the steel and copper will adhere to fresh nickel plating.

Copper has unique properties like softness, ductile, and malleability with very high thermal and electric conductivity.This makes it ideal for engraving. The cylinders are placed in PLC controlled copper bath using high purity copper nuggets to ensure uniform layer of copper and achieve the desired hardness & grain structure.

The plated cylinders are the loaded on to polishing machines. Polishing and finishing exercise enables the copper plated cylinders to attain geometric precision.

Engraving is carried out at SSG using high end state of the art electronic engraving machines from Hell Gravure Systems. The finalized designs are engraved onto the spinning cylinders with remarkable accuracy by using specialized diamond tips that rapidly vibrate to engrave the image. The engraving machines are controlled through proprietary software, as well as graphical user interface for Automatic cell display, calibration, and mechanical operation.

The unprotected copper layer is soft and prone to damage. So, the cylinders are chrome plated for their longevity. Chrome plating attains the corrosion deterrence on copper and protects the engraved surface from wear and tear caused by extensive usage the cylinders go through, during the long printing press runs.

The proofing process enables us to simulate the printing process in real life scenario. The engraved cylinders are loaded onto the proofing machines and the images are printed. This validation enables us to check the print proof and accuracy of the colors &design before we ship the cylinders to the customers.

Quality is the bedrock of our operations. We have stage-wise quality inspection at every cycle of our production process to ensure strict quality adherence. The stringent quality checks ensure we provide the best of class products for our customers. Apart from this there are quality checks in the packaging of the cylinders to avoid physical damage during dispatch.