Subrata Bose unveils UFlex's innovative FlexiTubes and many industry firsts

Subrata Bose, senior vice president and business Head of tubes at UFlex, recently showcased the group's advancements in the tube packaging industry. He highlighted UFlex's FlexiTubes, which uses high-definition reverse rotogravure printing and customisation of web as per customer choices, enabling  diverse decorative finishes, embedding holographic features, with the options of incorporating fully recyclable structures and PCR integration. This, he stated, allows brands to combine strong shelf appeal with sustainable solutions.

Bose further underscored UFlex's key 'firsts' in the laminate tube industry, both globally and in India. He noted, in what was a global pioneering effort, that UFlex was the first laminate tube company worldwide to offer fully reverse-printed flexible tubes using high-definition rotogravure technology. Additionally, Bose highlighted that the group was the first in India to introduce True 360 Print in laminate tubes, enabling full 360° seamless printing on these products.

Demystifying UFlex's strategy for seamless True 360 deg decoration on laminate tubes, Bose detailed their manufacturing process. With this innovation, UFlex challenges conventional approaches through design thinking, reimagining material selection, printing, lamination, and production processes to deliver customised solutions tailored to customer needs. Bose explained how this breaks aesthetic boundaries by offering seamless 360° prints and luxurious finishes using rotogravure reverse-printed tubes. It also allows the customer the option of choosing mono-material structures and high Post-Consumer Recycled (PCR) content, with the PCR produced entirely in-house.

When probed about the advantages of gravure printing in the manufacturing of tubes, Bose said that UFlex's gravure reverse-printed tubes deliver ultra-HD resolution, providing richer, more vibrant colours and sharp branding. "Gravure ensures photorealistic imagery, which is ideal for cosmetic and beauty packaging, enabling lifelike visuals that elevate brand perception and drive shelf appeal," he said. He further explained, "There is exceptional detail and gradient control. Since gravure excels at producing high-resolution images, fine details, and smooth colour transitions." In terms of consistent colour reproduction, Bose stated, "It ensures minimal variation across long print runs, maintaining a uniform, high-quality appearance."

Finally, Bose noted that UFlex's approach can accelerate launch times. "UFlex utilises vertical integration and end-to-end expertise, covering material science, gravure/flexographic printing, lamination, holography, anti-counterfeiting solutions, and in-house PCR, all under one roof," he elaborated. The result, Bose concluded, is unique, brand-centric packaging that stands out, enhances consumer experience, and is future-ready and sustainable.

The Noida-based group is also the first in India to commercially produce and supply paper-based tubes, known as Kraftika. Bose shared with WhatPackaging? that UFlex is India’s first tube manufacturer to locally produce and commercially supply paper-based laminate tubes with up to 45% paper content in the sleeve. As reported by WhatPackaging? magazine in 2019, UFlex commercially launched Kraftika as an innovative paper-based laminate tube that significantly reduces plastic usage at the source, achieving up to 45% plastic reduction.

Key features of Kraftika include its composition from virgin Kraft paper, boasting low COBB value and high bursting strength. When asked about Kraftika's moisture resistance, Bose explained, "An option of a reverse-printed BOPP layer provides effective moisture barrier protection." Showcasing several Kraftika samples, Bose underscored, "The matte finish surface and underlying brown paper offer an authentic, eco-friendly look and feel. Plus, it is compatible across multiple tube diameters."

UFlex is also the first to introduce embedded holographic security for anti-counterfeiting in laminate tubes. As Bose highlighted, "UFlex is the first tube company in India to integrate advanced holographic effects, including Fresnel lensing, and overt and covert anti-counterfeiting features, embedded directly into laminate tubes." He reiterated to WhatPackaging?, "UFlex tubes outsmart counterfeiters through embedded holographic security features. UFlex is the first tube company in India to integrate advanced holographic effects, including lensing, and overt and covert anti-counterfeiting features, directly into laminate tubes."

One common question our customers often ask is how our technology adapts to low MOQs, especially since many brands may not have high volumes at launch. Flexitubes can seamlessly switch to digital printing or flexo in reverse printing, instead of using Rotogravure, while retaining all the key performance benefits of our solution. This flexibility allows us to effectively support emerging or niche product lines without compromising on quality, speed, or shelf appeal.

Finally, UFlex stands as the first and only laminate tube manufacturer in India with in-house PCR integration. This capability allows them to offer PCR tubes using in-house produced Post-Consumer Recycled resin, ensuring true circularity and full traceability. Bose informed WhatPackaging?, "What sets these tubes apart is that the raw material used in the PCR tubes is sourced internally through UFlex’s integrated recycling and manufacturing infrastructure, ensuring consistent quality, supply reliability, and a reduced environmental footprint."

UFlex's vertical integration and end-to-end expertise encompass material science, gravure/flexographic printing, lamination, holography, anti-counterfeiting solutions, and in-house PCR, all managed under one roof. The result, as Bose stated, "Is unique, brand-centric packaging that stands out, enhances consumer experience, and is future-ready and sustainable."