DRATHORE – BLOG

DR Optical Disc India Pvt. Ltd. Successfully Installs Laminated Tube Manufacturing Plant in Baddi

State-of-the-Art Equipment Includes UV Laminate Printing Machine, High-Speed Tube Body Line, and Precision Shoulder Heading Machine

Baddi, Himachal Pradesh — In a major boost to the packaging infrastructure of northern India, DR Optical Disc India Pvt. Ltd. has successfully supplied and installed a complete laminated tube manufacturing plant in Baddi, a key industrial hub in Himachal Pradesh. Equipped with cutting-edge machinery and capable of producing 100 laminated tubes per minute, the plant is a testament to DR Optical’s expertise and leadership in turnkey cosmetic and pharmaceutical tube packaging solutions.

This installation marks a significant milestone not only for the client in Baddi but for the Indian packaging industry at large, as the demand for laminated tubes continues to surge—driven primarily by the booming pharmaceutical and personal care sectors.

A Fully Integrated Tube Manufacturing Line

The newly commissioned plant features a comprehensive production line, from printing and tube forming to heading and finishing. The equipment supplied by DR Optical includes:

1. Kopack 250 6-Color Rotary Letterpress Full UV Laminate Printing Machine
2. Lamitube Body Making Line ( max speed of 30 meters per minute )
3. Fomtec Shoulder Heading Machine

Together, these machines offer a seamless, high-speed, and high-quality production workflow, enabling manufacturers to produce aesthetically appealing and structurally durable laminated tubes at scale.

1. Kopack 250: Precision UV Laminate Printing

The first phase of the tube manufacturing process is printing, and the Kopack 250 rotary letterpress machine ensures this is done with exceptional clarity, color accuracy, and adhesion.

Key Features of the Kopack 250:

• 6-color printing capabilities, allowing vibrant, multi-shade graphics and branding elements.
• Full UV curing system, which provides instant drying of ink layers for smudge-proof, high-resolution prints.
• Rotary letterpress configuration, which delivers precise and repeatable prints on laminated web material, essential for high-end cosmetic and pharma applications.
• Advanced registration controls for consistent quality across high-speed runs.
• UV VArnish unit, which provides a coating of UV Varnish to protect the printed surface and gives and aesthetic appeal.

The machine has been integrated with inline quality control systems, ensuring that each printed web meets stringent aesthetic and regulatory standards. The UV-based curing system is also more environmentally friendly, emitting fewer volatile organic compounds (VOCs) than conventional drying systems.

2. Lamitube Body Making Line: Speed Meets Structural Integrity

Once the web material is printed and cured, it is fed into the Lamitube body making line, which converts it into tube sleeves. Operating at a linear speed of 30 meters per minute, this system offers a perfect blend of speed, consistency, and strength.

Core Functions of the Body Making Line:

• Tube cutting: Precisely trims the printed web into tube-length segments.
• Edge sealing: Uses advanced heat sealing mechanisms to create seamless, leak-proof side welds.
• Tube shaping: Forms the cut and sealed material into cylindrical tube bodies, ready for heading and capping.

Designed with servo-controlled drives and PLC automation, the line delivers precise control over dimensions, seal quality, and tube strength, even at maximum speeds.

3. Fomtec Shoulder Heading Machine: The Final Touch

The last but critical step in the laminated tube production process is the attachment of the shoulder and neck of the tube. The Fomtec shoulder heading machine installed at the Baddi plant offers high accuracy and flexibility, capable of handling different neck designs and materials.

Highlights of the Fomtec Heading Machine:

• High-speed shoulder fixing matched to the line’s throughput of 100 tubes per minute.
• Multiple mold sets for various diameters and shoulder shapes.
• Efficient cooling and ejection systems for minimal downtime.
• Excellent fusion strength, ensuring the shoulder is securely bonded with the tube body.

This machine also ensures that the shoulder and cap threading is aligned and centered, providing users with a smooth experience when dispensing product from the tube.

Plant Production Capacity: 100 Tubes per Minute

With the synergy of these three machines, the newly installed plant in Baddi is capable of producing 100 laminated tubes per minute, making it one of the most efficient and high-output facilities in the region. This capacity translates to an annual production potential of over 50 million tubes, depending on shift patterns and tube size.

India’s Pharmaceutical Growth Fueling Tube Packaging Demand

India’s pharmaceutical sector, now ranked third globally in volume, is witnessing exponential growth, particularly in topical formulations, gels, creams, and ointments. Laminated tubes have emerged as the packaging format of choice due to their:

• Hygienic, tamper-proof design
• Barrier protection against oxygen, light, and moisture
• Sleek appearance and branding capability
• Portability and convenience

With the increased focus on export-ready packaging, Indian pharma companies are demanding international-grade packaging solutions, and DR Optical’s installations are directly meeting this need.

Moreover, the COVID-19 pandemic accelerated demand for hand sanitizers, creams, and hygiene products, further fueling the need for laminated tube production across India.

DR Optical Disc India Pvt. Ltd.: A Name Synonymous with Innovation and Excellence

Founded in 2008, DR Optical Disc India Pvt. Ltd. has evolved into a leading force in the supply of turnkey laminated tube and seamless PE cosmetic tube manufacturing projects across India and overseas. With over a decade of experience, the company offers:

• Complete technical and commercial project consultancy
• Custom equipment selection from the best suppliers
• Installation and commissioning
• Operator training and post-sale technical support

The company has a team of highly qualified engineers, technicians, and project consultants who work closely with clients to understand their specific production needs and market goals.

DR Optical’s solutions are not just limited to machinery—they offer a complete ecosystem of support, enabling new entrants and established players alike to scale up with confidence and precision.

Turnkey Execution: From Blueprint to Reality

One of DR Optical’s core strengths lies in end-to-end project execution. In the Baddi project, their role encompassed:

1. Consultation & Planning – Assessing client needs, production targets, and investment goals.
2. Equipment Customization – Recommending the right mix of machinery for target tube formats and production volume.
3. Installation & Calibration – Precision setup of machines, ensuring alignment, power integration, and safety compliance.
4. Training & Handover – On-site training of operators and maintenance teams to ensure independent, efficient operations.
5. Ongoing Support – Routine maintenance schedules, spare parts provisioning, and remote diagnostics support.

This integrated approach minimizes startup challenges and ensures a fast ROI for clients.

Sustainability and Efficiency: Built for the Future

DR Optical’s solutions are designed with the environment and future scalability in mind. The Baddi plant, for instance, incorporates:

• Low-energy UV curing systems to reduce power consumption
• Waste minimization systems to limit material loss
• Precision-cutting tools that reduce scrap
• Expandable modular setups, allowing for capacity upgrades

These features help clients meet both economic and environmental objectives, crucial for modern manufacturers facing increasingly strict ESG (Environmental, Social, Governance) norms.

Client Testimonials and Industry Recognition

The success of the Baddi plant has garnered praise from both the client and industry observers. The client has lauded DR Optical’s professionalism, technical prowess, and on-time execution.

A senior executive from the client company stated:

“We were looking for a reliable partner who could not only deliver machines but also guide us through every step of setting up a high-speed laminated tube facility. DR Optical exceeded our expectations.”

The facility is now positioned as a benchmark plant for laminated tube production in the northern belt of India.

Looking Ahead: DR Optical’s Vision for the Industry

DR Optical Disc India Pvt. Ltd. continues to lead with innovation, customer focus, and quality engineering. With several upcoming projects in the pipeline and increasing demand from the export and domestic sectors, the company is expanding its portfolio to include:

• Multi-layer PE Cosmetic tube manufacturing lines
• Laminated ABL / PBL tubes manufacturing lines
• BOPP Film carton overwrapping solutions
• Shrink sleeve applicators
• Labelling solutions for Bottles and cartons

DR Optical envisions playing a critical role in India’s transition to world-class packaging standards, especially in the fast-growing personal care, cosmetic, and pharma industries.

Conclusion

The successful installation of a laminated tube manufacturing plant in Baddi by DR Optical Disc India Pvt. Ltd. is more than just a business achievement—it is a strategic contribution to India’s growing industrial ecosystem. With high-end machinery like the Kopack 250 UV printing press, 30 m/min Lamitube body making line, and Fomtec heading machines, the facility is set to serve the needs of India’s evolving packaging landscape.

As demand for sustainable, high-quality, and visually appealing tubes grows, DR Optical stands ready—offering complete turnkey solutions, technical excellence, and a vision aligned with the future of Indian manufacturing.

DR Optical Disc India Pvt. Ltd.