A seven-colour Rapida 106 in a double-coater configuration will be entering production at Deluxe Packages in Karachi/Pakistan in autumn. It is the longest sheetfed offset press ever installed in the 60‑year history of the company, which supplies packaging for the pharmaceuticals, cosmetics and confectionery branches, as well as POS displays. Rehan Shafi Siddiqui and Zeeshan Mustafa Shafi Siddiqui represent the second generation at the helm of the family business. They are in full agreement: “We were looking to invest in the very latest technology, and the Rapida 106 was thus a logical choice. Our confidence in KBA and the local sales team from Imprint Packaging Solutions was paramount in this decision.”

Deluxe Packages today occupies more than 4,000 m2 (43,560 sq ft) of production space at its existing premises. A new factory adds a further 16,000 m2 (174,240 sq ft). With more than 150 employees, the company generates an annual turnover of around $5.5 million (approx. €5 million) and is one of the leading packaging companies in Pakistan. In the past, the company has used various half- and medium-format presses with four to six colours, and so the arrival of the 11-unit Rapida 106 heralds the transition to a whole new dimension. The postpress department is also dominated by the latest die-cutting and folder-gluer technologies. As the packaging market in Pakistan is currently undergoing rapid change, it is essential for companies like Deluxe Packages to match their equipment and technology options to future demands.

Increasing complexity in packaging production

The print format and production output of the Rapida 106 are important factors for the company. The increasing complexity of packaging designs calls for additional printing units for spot colours, and the double-coating facility is a further prerequisite for high-quality multiple coatings and UV finishes. The press is prepared for mixed conventional/UV production, features 450 mm raised foundations and incorporates dedicated accessory packages for both board and plastics printing. Its automation includes fully automatic FAPC plate changers, CleanTronic Multi washing systems for the alternating use of different ink systems, and CleanTronic UV.

The commissioning of the Rapida 106 will lend a clear boost to productivity and quality in the press room. At the same time, it will further expand the company’s substrate flexibility into the fields of plastic packaging and production on metallised board with an opaque white primer. “The Rapida 106 is known for its high productivity, and KBA is an expert for the precise tailoring of special presses to individual packaging applications. The UV equipment from KBA is likewise a superior system” – convincing conclusions yielded by market research conducted by the two company directors.

Future-oriented productivity and quality

Deluxe Packages operates a two-shift system and prints around 35 million sheets per year … with further increases planned! Its market success is achieved through a mix of innovative technology and concentrated customer orientation. The Rapida 106, with its comprehensive process capabilities, is certain to contribute to further growth with high-quality printing and finishing. The additional installation of a cold foil module is in the pipeline and will soon add yet another aspect to the application spectrum.