/ 13-stage production process
From artwork to dispatch, in 13 quality-gated steps.
Three phases - Design & Pre-Press, Supply Chain & Print, Quality & Logistics - each with structured checkpoints. Every roll leaves Baddi with a digital eCOA and full traceability back to incoming raw material inspection.
- 01 · Phase 1 · Design+Artwork & specs ingest
Soft copies and technical specs received from the client - PDF, AI or PSD. Colour schemes, fonts, dimensions, and embellishment effects are locked in at this stage.
- 02 · Phase 1 · Design+Prepress & colour proof
Proof printouts strictly verified by internal QC before client sign-off. Pantone matching, trap settings, and regulatory compliance layers checked in full.
- 03 · Phase 1 · Design+Tooling & plate make
Precision dies and photopolymer plates sourced and mounted. Plate-registration tolerance held to ±0.02 mm across all Gallus and Bobst lines.
- 04 · Phase 2 · Supply+Raw material allocation
Substrate and adhesive rolls allocated based on volume, finish spec and run plan. Avery, UPM, SMI and MLJ stock held on-site for 70+ active SKUs.
- 05 · Phase 2 · Supply+Incoming QC (IQC)
Every incoming ink and paper batch tested for GSM, caliper, release force and colour strength before release to the press floor.
- 06 · Phase 2 · Supply+High-speed printing
Production runs on Gallus 10-colour (screen + gravure + hot foil inline), Gallus 8-colour flexo and Bobst 8-colour flexo lines with continuous register checks.
- 07 · Phase 2 · Supply+Matrix stripping
Waste matrix cleanly stripped inline or via standalone die operations. Zero-tension winding preserves label flatness for automatic labelling machinery.
- 08 · Phase 2 · Supply+Embellishments
Offline hot-foil stamping, cold-foil stamping, rotary screen and custom sheeting applied as specified - all in-house with very short turnaround times.
- 09 · Phase 3 · QA+AVT 100% inline inspection
Every label scanned by twin Israel-made AVT Automatic Inspection Systems. Registration, colour, barcodes and print defects all detected at line speed. Zero-defect supply guarantee.
- 10 · Phase 3 · QA+Master roll slitting
Master rolls slit into target ribbon widths and exact label counts per your labelling machine spec - OD, core size and pitch all verified.
- 11 · Phase 3 · QA+Packaging & tracking
Rolls shrink-wrapped, boxed in corrugated cartons and labelled with tracking slips including batch, count, and substrate details for full lot traceability.
- 12 · Phase 3 · QA+eCOA clearance
Digital Certificate of Analysis generated and signed off by QC before dispatch. Includes AVT report, colour verification data and regulatory compliance statement.
- 13 · Phase 3 · QA+Dispatch
Rolls shipped out seamlessly alongside digital eCOA clearance. Tracking details shared with the client the moment the consignment leaves the facility.