DRATHORE – BLOG

Kaizen Manufacturing Company Pvt. Ltd. Launches Advanced PE Cosmetic Tubes Manufacturing Unit in District Nainital

In a significant leap forward for India’s packaging and cosmetic manufacturing industry, Kaizen Manufacturing Company Pvt. Ltd. has inaugurated a state-of-the-art PE cosmetic tubes manufacturing unit in the dust and pollution free location of District Nainital, Uttarakhand. This landmark facility not only marks a milestone for the region’s industrial development but also introduces cutting-edge manufacturing technologies to the Indian cosmetic packaging sector.

The new plant is equipped with some of the most advanced machinery in the world, making Kaizen a pioneering player in the field of extruded multilayer PE tubes, especially for the fast-growing personal care, beauty, and pharmaceutical sectors. The entire facility has been thoughtfully designed and established in close consultation with DR Optical Disc India Pvt. Ltd., a renowned name in industrial equipment and project consultation.

First in India: 6-Layer Extrusion Technology

At the heart of the manufacturing unit is India’s first 6-layer extrusion machine, a game-changer in the cosmetic tubes industry. Traditionally, most extrusion systems in India operate with 3 or 5 layers. The 6-layer extrusion technology employed by Kaizen offers enhanced barrier properties, superior tube strength, and greater flexibility for customized compositions.

This advanced extrusion capability ensures that the tubes can provide better protection against light, air, and other environmental contaminants — critical for preserving the integrity of cosmetic and pharmaceutical products. The inclusion of additional layers also improves the tactile feel, aesthetics, and overall consumer experience.

Automated and Semi-Automated Shoulder Heading Machinery

Another key feature of the plant is its automatic and semi-automatic shoulder heading machines, which are integral in forming the shoulders of the tubes that attach to various types of caps. The hybrid configuration enables high-volume production while also allowing flexibility for shorter runs and custom designs.

The shoulder heading process, which involves attaching the moulded shoulder to the extruded tube body, has been optimized to maintain exceptional precision and strength. The combination of automatic and semi-automatic systems ensures both speed and accuracy, minimizing production defects and increasing operational efficiency.

Various options available in shoulder heading are screw type, push fit, oval, nozzle and lip balm.

High-End Tube Decoration: 6-Color Offset Printing

A standout feature of the Kaizen facility is the 6-color offset printing machine for tubes — a sophisticated system designed for high-quality, multi-color decoration of PE tubes. Offset printing is known for its ability to produce vivid, detailed, and durable images on cylindrical surfaces, and Kaizen’s 6-color setup takes this to a new level of creativity and branding.

This allows brand owners to print vibrant graphics, complex color gradients, and precise text — enhancing the shelf appeal of their products in a highly competitive market. It also supports UV curing quick-dry inks with UV varnish, enabling faster production times and reduced downtime between runs.

PE Tube Screen Printing with Hot Stamping

To further enhance product aesthetics, Kaizen has also introduced screen printing with hot stamping capabilities. Screen printing offers excellent opacity and vivid color reproduction, especially on curved and flexible tube surfaces. Combined with hot stamping, which applies metallic foils for luxurious effects, this process creates a premium look and feel highly sought after in the cosmetic industry.

Whether it’s a bold logo, a metallic border, or a unique design element, this combination allows Kaizen’s clients to achieve a high-end appearance without compromising durability or production speed.

Advanced Capping Solutions: Automatic Cap Fitment

Capping is a critical aspect of tube manufacturing, affecting both product security and user experience. Kaizen has installed two dedicated automatic capping machines, one for screw-type caps and another for push-fit type caps. This specialization ensures high throughput, accurate torque control, and uniform sealing, irrespective of the cap design.

The automated systems reduce the need for manual intervention, decreasing the chances of cross-contamination and ensuring hygienic conditions — a crucial requirement for cosmetic and pharmaceutical packaging.

Cap Decoration: Shrink Sleeving Machine

Kaizen’s commitment to detail extends even to cap decoration, with the integration of a cap shrink sleeving machine. This machine applies decorative or tamper-evident sleeves to caps, enhancing branding while providing additional security to the end product.

Consultation and Execution by DR Optical Disc India Pvt. Ltd.

The entire plant setup and machinery installation have been expertly guided by DR Optical Disc India Pvt. Ltd., a company known for its excellence in industrial equipment consultation and precision manufacturing systems. Their input has been instrumental in optimizing plant layout, equipment selection, and automation integration to achieve global manufacturing standards.

By leveraging DR Optical’s technical expertise, Kaizen has managed to reduce setup times, enhance machine calibration, and streamline workflow — all of which contribute to a highly efficient and quality-driven manufacturing environment.

Impact on the Region and Industry

The establishment of this high-tech manufacturing unit in District Nainital is expected to have a positive ripple effect on the local economy. It brings new employment opportunities, enhances the region’s industrial profile, and paves the way for future investments in high-end manufacturing technologies in Uttarakhand.

From a national perspective, Kaizen’s facility strengthens India’s capability to produce world-class cosmetic packaging solutions domestically, reducing dependency on imports and positioning the country as a competitive player in the global market.

Commitment to Quality and Sustainability

While the primary focus is on innovation and efficiency, Kaizen Manufacturing Company Pvt. Ltd. is equally committed to sustainability and environmental responsibility. The manufacturing plant follows stringent quality and environmental management protocols. Plans are also in place to explore biodegradable and post-consumer recycled (PCR) material integration in the future.

Looking Ahead

With its world-class facility, Kaizen is poised to serve not only Indian cosmetic brands but also global clients looking for premium packaging partners. The combination of technological innovation, quality assurance, and sustainability makes Kaizen a formidable new entrant in the PE cosmetic tube manufacturing landscape.

As demand for innovative, attractive, and eco-friendly cosmetic packaging continues to rise, Kaizen Manufacturing Company Pvt. Ltd. is well-positioned to lead the way with its vision, capability, and commitment to excellence.

Contact Details

Vaaswee Sharma ( CEO )
Kaizen Manufacturing Company Pvt. Ltd.
Khasra No. 974-75, Gintigaon, Kotabagh, Kaladhungi,
District Nainital, Uttarakhand, -263159 – India
contact@kaizenmfg.com; www.kaizenmfg.com
+91 78170 94276