Monarch Graphics | 115Monarch Graphics 2.0 Indian label converter Monarch Graphics has set up a second production unit with a new Gallus Labelmaster press alongside slitting, die-cutting and inspection equipment. Akanksha Meena reports stablished in 2006 by Pavail Jain, father of techno-commercial director Bhrigav Jain, Monarch started as a small team of 10 including the father and son. EMonarch’s initial infrastructure revolved around a used single color offset machine converting tags and a fatbed die-cutting machine for blank label conversion, along with a used intermittent Iwasaki letterpress machine to print barcode labels.In 2011, Monarch invested in a 7-color Orthotec letterpress machine. In 2015, it acquired its frst Gallus ECS 340 9-color fexo press with a rotary screen unit – a rare confguration at the time in Delhi NCR, Bhrigav Jain says. The company devoted itself to mastering the fexo process, implemented ERPs and gained certifcations. It invested in custom training programs from Gallus to learn new printing processes and Bhrigav Jain, techno-commercial director of Monarch, with his new Gallus Labelmaster 440 fexo pressachieve the best out of its technology.In 2021, the company decided to expand with a second production unit and invested nearly 1.09 million USD in its “Adding new products is the goal 18,000sqft in Noida that houses its second Gallus press along with slitting, die-cutting and inspection equipment.of the organization. The next two The new manufacturing facility will enable the company to meet the demands of current and future customers, more than double years will provide a base for what we production capacity, and create new jobs within the company. produce after 2025. This plant will Jain plans to produce complex labels and reduce wastage with the new set-up. He says that it has been designed for a lean fuel growth for the coming fve years”manufacturing process and to address manpower challenges. The foor layout has been designed to foster internal communication and eliminate unnecessary wastages by of waste and at the same time to be innovative,’ he says.streamlining the production process. Monarch has obtained G7 certifcation on the new Gallus press and is working to maximize standardization of its processes in the Second Gallus quality of products. Before buying the Gallus Labelmaster 440, Jain visited multiple ‘G7 is a diffcult process to achieve in fexo printing and by fexo press manufacturers and traveled extensively to understand doing that we are hoping to fully stabilize the process. We fully their products. understand the machine and its capabilities. We are stabilizing Why another Gallus? Jain says that buying technologically the process in day-to-day printing so that we can provide them proven products has always been a push from his father, who has G7 print.’ never compromised on technology. ‘There were several reasons for The Luster inspection system has enabled Monarch to eliminate Monarch to opt for another Gallus press,’ he says. ‘We have adapted human errors. The machine detects errors such as missing print data to the machine and its UI and had complete confdence in machine and shade variations, and inspects variable data. manufacturing process and its stability at higher speeds. Seeing an It also invested in UV inkjet head to print variable data on labels. open machine, how it is confgured and its accuracy, was crucial.’ ‘We have further ancillaries from reputed companies such as JM In addition, he cites Monarch’s relationship with Gallus a Heaford and RotoMetrics,’ adds Jain. contributing factor. The company aims to have annual revenue of 5.4 million Earlier, the plan had been to invest in a hybrid press that USD by end of 2024. To achieve this, Jain is looking to enter the could perform both digital and fexo functions. At one point, Jain in-mold and shrink sleeve segments and invest in more converting considered investing in both digital and fexo presses for his new equipment. The company is considering investing in another fexo plant but it was not an economically feasible option. press in 2023 to target new label sectors. ‘At Labelexpo Europe 2019, I saw a few applications that only ‘Adding new products is the goal of the organization. Lots of our the Labelmaster was showcasing and which really fascinated me. customers have requirements for in-mold and shrink sleeves. The We decided to buy a good fexo press with not too many bells and next two years will provide a base for what we produce after 2024. whistles and not for the glory shot, as they say in cricket.’ This plant will fuel growth for the coming fve years.’ The 10-color Gallus Labelmaster is equipped with multiple in-line Jain hints that considering his experience with the press converting options such as rotary screens, dual cure drying systems manufacturer, he might go for another Gallus press. ‘Having a and auto registration, special print units for in-line embellishments similar machine is always useful from the training perspective of along with several converting options. staff. And the relationship with the manufacturer is important for Monarch is running both short and long runs on the press with an quick service in times of crisis and support of the entire local team average run length of 1,500-2,000 meters. present in India.’ ‘The Gallus team made the installation really smooth and today Monarch will increase its exports to the US and Europe for high I am very happy I made this decision. It is helping us to reduce a lot end decorative labels. The company currently exports 20 percent of Jan - Mar 2022