DE Converter installs Gallus Labelmaster 440 to boost high-performance label and flexible packaging output

INDIA — Kolkata-based DE Converter has strengthened its manufacturing capabilities with the installation of a Gallus Labelmaster 440, marking a major boost for the company’s label and mid-web flexible packaging operations.

The eight-colour press, equipped with dual die-cutting stations and cold-foil capability, positions the converter for higher throughput, reduced waste, and increased agility in a rapidly expanding packaging market.

The investment reinforces DE Converter’s commitment to high-efficiency flexo printing as demand for short-run premium packaging, FMCG labels, and tea tags accelerates across Eastern India.

Designed for versatility, the Labelmaster 440 supports a maximum mechanical speed of 200 m/min and accommodates a web width of 445 mm.

Its standout feature is a 1.4-meter short web path between print units, significantly reducing setup waste and makeready material consumption.

Strategic growth backed by 75 years of operations

Established in 1950, DE Converter has evolved into a diversified organization spanning laminates, machinery manufacturing, and confectionery packaging, with revenues exceeding US$22.5 million.

As consumer markets shift towards faster delivery cycles and e-commerce accelerates regional demand for packaging SKUs, the company recognized the need to transition to a more automated printing platform.

“Today’s packaging market demands speed, agility, and efficiency,” said Sandip Kundu, Director at DE Converter. “We needed a super-efficient press that could deliver faster changeovers, reduced waste, and support a wide range of substrates.

“The Labelmaster enables us to operate with fewer operators and handle urgent requirements confidently. It’s an investment in resilience as much as growth.”

The press’s servo-driven architecture ensures precise register control at all speeds, improving consistency across long and short runs.

Trials conducted at the Gallus demo centre in Pune validated its ability to run challenging substrates, from uncoated papers to ultra-thin 12-micron polyester, critical for DE’s expanding premium flexible packaging portfolio.

Capacity expansion and market alignment

DE Converter expects immediate production gains, projecting output to rise from 70–80 tons per month to nearly 100 tons.

With India’s packaging sector forecast to grow at a CAGR of 26.1% through 2030, driven primarily by flexible packaging, such upgrades support stronger competitiveness and margin expansion.

The company anticipates up to 25% profitability improvement from waste reduction, higher speeds, and increased automation.

Thomas Frank, Managing Director of Heidelberg Asia Pacific, noted, “India is at the forefront of global growth in labels and packaging. With the Gallus Labelmaster, converters like DE are scaling capacity while remaining cost-competitive, efficient, and future-ready.”

The new press sets the foundation for DE Converter’s upcoming 14-acre greenfield facility in West Bengal, which will feature extrusion lines, roll-trim operations, and next-generation converting technology, positioning the company to meet both domestic and international demand with greater reliability and scale.

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