Our in-house design department is equipped with advanced graphic software and experienced designers to prepare print-ready artwork for rotogravure cylinder engraving. We ensure accurate color separation, layout alignment, and repeat size preparation as per printing requirements. The team works closely with customers to finalize designs that meet brand expectations and packaging standards.

The pre-press department converts approved artwork into engraving-ready files with precise technical parameters. We perform cylinder repeat calculations, step & repeat layout, color channel separation, and resolution optimization. This stage ensures proper image positioning, consistent color output, and smooth transition to the engraving process.

In the fabrication department, high-quality base shell cylinders are manufactured with precision engineering and strict quality control. We use premium-grade base shell cylinders with heavy and uniform wall thickness, ensuring superior strength and stability during high-speed printing. The robust construction helps maintain perfect concentricity and minimizes vibration, resulting in accurate engraving and consistent print performance. This strong foundation plays a crucial role in achieving long cylinder life and excellent engraving quality

The fabricated cylinders undergo copper plating in our advanced galvanisation department. We use the best quality copper in the industry, specially sourced from Luvata, Malaysia, known for its high purity and consistent electroplating performance. The base cylinder is immersed in controlled electroplating tanks where a uniform copper layer is deposited. This premium copper coating ensures excellent surface smoothness, optimum hardness, and superior engraving results, enabling high-quality ink transfer and consistent print output.

After copper plating, cylinders are polished using high-precision polishing machines. This process ensures correct circumference, surface roughness, and parallelism of the cylinder. Proper polishing is essential to achieve uniform engraving depth and high-quality print output.

Our engraving department is equipped with advanced rotogravure engraving machines capable of producing high-resolution cells. The design is engraved onto the copper surface with precise cell geometry to control ink transfer and print density. This stage ensures sharp text, smooth gradients, and consistent print quality across the entire cylinder.

After engraving, cylinders undergo hard chrome plating to protect the engraved surface. The chrome layer enhances wear resistance, improves durability, and protects against ink, chemicals, and doctor blade friction. This ensures longer cylinder life and stable performance during high-speed printing.

In the final stage, cylinders are tested on proof press machines to verify engraving accuracy and print quality. We check image clarity, color density, registration, and repeat alignment. Customers can review the proof before final dispatch, ensuring complete satisfaction and error-free production.

After approval, cylinders are carefully packed using protective materials to avoid scratches or physical damage during transportation. Each cylinder is labeled and dispatched safely to maintain quality till installation at the printing press.