Infrastructure &
Manufacturing Plant
Celesta Exim operates a specialized flexible packaging converting facility in the industrial corridor of Bakrol Bujrang, Gujarat. Built for precision converting, our plant integrates in-house 8-color rotogravure printing presses, solvent-less multi-layer lamination lines, high-speed slitters, and pre-formed pouch machines certified under ISO 9001:2015 quality standards.
Facility Overview:
Engineered for B2B Converting Reliability
Our manufacturing site is organized for linear converting workflow, strict dust control, and contamination prevention required for certified food-contact packaging materials.
Core Converting Equipment
& Production Parameters
Structured equipment cards reflecting actual production parameters, working web widths, and mechanical capabilities without unverified capacity claims.
High-Speed Rotogravure Printing Press
Primary Printing Line • Up to 8/9 Color StationsEquipped with independent drying chambers, computerized optical register control, and automated stroboscopic video web inspection cameras scanning for pinhole flaws and register deviation.
| Number of Colors: | Up to 8 Colors in single continuous pass |
|---|---|
| Working Web Width: | 400 mm to 1,200 mm |
| Operational Speed: | Up to 250 - 300 m/min calibrated line speed |
| Compatible Substrates: | PET (10–50µ), BOPP (15–40µ), Paper, Pearlized Films |
| Registration Accuracy: | ± 0.1 mm micro-electronic tracking |
Solvent-Less Multi-Layer Laminator
High-Barrier Multi-Substrate BondingUtilizes 100% solids polyurethane solvent-less adhesive technology, completely eliminating VOC emissions and residual solvent odor retention in food and pharmaceutical packaging.
| Lamination Process: | Solvent-less Adhesive (2-ply, 3-ply & 4-ply) |
|---|---|
| Working Width: | Up to 1,200 mm web width |
| Materials Bonded: | PET, MET-PET, Pure Aluminum Foil, Nylon (PA), PE, CPP |
| Tension Control: | Closed-loop digital load cell tension regulation |
| Food Safety Compliance: | Zero solvent retention • US FDA 21 CFR § 177.1520 |
High-Precision Slitting & Rewinding Units
Roll Slitting & Edge Position ControlComputerized dual-shaft rewinding equipped with ultrasonic web edge sensors, delivering telescope-free, straight-edge finished reels calibrated for automated VFFS packaging lines.
| Slitting System: | Razor blade in groove & rotary shear cutters |
|---|---|
| Min / Max Slit Width: | 50 mm up to 1,200 mm custom slit width |
| Rewind Core Diameter: | 76 mm (3 inches) standard paper cores |
| Max Rewind Diameter: | Up to 600 mm outer diameter (OD) |
| Edge Alignment: | Automatic web guiding < 0.5 mm deviation |
Multi-Format Pouch Converting Line
Stand-Up, 3-Side Seal & Spout ConvertingPrecision pouch making machinery engineered with continuous heat sealing bars, pneumatic hole punchers, zipper insertion units, and ultrasonic fitment welders.
| Pouch Configurations: | Stand-Up (Doypack), 3-Side Seal, Side Gusset, Spout |
|---|---|
| Pouch Width Range: | 70 mm to 400 mm |
| Pouch Height Range: | 100 mm to 600 mm |
| Integrated Add-ons: | Press-to-close zippers, tear notches, euro-slots, spouts |
| Seal Hermeticity: | 100% vacuum chamber leak verified |
Printing & Converting Operations:
In-House Precision vs. Specialized Sourcing
As mandated by transparent B2B reporting standards, we clearly define which conversion phases take place in our Bakrol Bujrang plant versus verified raw material supplier operations.
Pre-Press Proofing & Cylinder Setup
Artwork color trap separation, electronic cylinder calibration, and digital proof generation managed in-house; base steel cylinder machining performed with certified engraving partners.
Rotogravure Reverse Printing
Executed entirely in-house on our multi-station rotogravure presses. Reverse printing on transparent PET/BOPP ensures ink is encapsulated and protected from scuffing.
Solvent-less Adhesive Lamination
Executed 100% in-house. Multi-substrate lamination (PET/Foil/PE, MET-PET, Nylon) using zero-VOC food-contact polyurethanes with precise nip pressure control.
Slitting, Pouching & Export Packaging
Slitting, reel core capping, pouch fabrication, and ISPM-15 wooden palletization executed in-house under cleanroom humidity-controlled dispatch zones.
Rigorous Quality Checks:
Certified Testing Equipment & Standards
Under our ISO 9001:2015 certified quality management system, every production batch is sampled and tested before dispatch. We maintain complete traceability records for raw polymer resin batches, cylinder numbers, and adhesive lots.
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Bond & Peel Strength Testing (Universal Tensile Tester): Verifies inter-ply adhesion across PET/Foil/PE layers to ensure zero delamination under mechanical stress.
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Heat Seal Hermeticity & Dwell Validation (ASTM F88 / F2029): Calibrates hot-tack and seal initiation temperature (SIT) to ensure leak-free performance on client packaging lines.
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Coefficient of Friction (COF) Testing (ASTM D1894): Measures static and kinetic slip values (0.20–0.25) to prevent web drag or necking on high-speed VFFS machinery.
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Vacuum Chamber Leak Testing (ASTM D3078): Submerges filled pouches in sub-atmospheric water chambers to detect micro-channel leaks and pinholes.
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Spectrophotometer Color Density & Registration Check: Electronic Delta E (< 2.0) verification against approved brand master color swatches and Pantone codes.
Inside Our Manufacturing Facility
Photographic documentation of our high-speed converting machinery, cleanroom slitting operations, and export palletization.
Roll Slitting
Automatic ultrasonic edge sensors eliminate reel telescoping for continuous VFFS packaging feeds.
Barrier Lamination
Zero-VOC lamination fusing PET, Aluminum Foil, and Polyethylene under controlled thermal nip pressure.
Pouch Conversion
Continuous converting of stand-up pouches with integrated press-to-close zippers and tear notches.
Cylinder Tooling
Electronically engraved rotogravure cylinders preserved in climate-controlled storage for repeat client runs.
Export Packaging
Heavy-duty core caps, desiccant bags, and shrink wrap protecting export consignments against sea transit humidity.
Plant Site
Strategically situated in Gujarat's prime industrial manufacturing hub with direct transport corridor connectivity.
Discuss a Project With
Our Plant Engineers.
Connect directly with our converting technicians to evaluate machine jaw compatibility, verify web slit width tolerances, or request plain sample reels for trial runs.
Technical & Machinery Inquiry Form
Submit your packaging machine model and target substrate specifications.