An interview from Mr.P.S.Paintal Managing Director, Zenith Rollers.
We provide total solutions for rubber roller refurbishing facilities under one roof, be it machinery, tools, features, QC equipment, raw materials comprising ready-to-use rubber compounds and cores, finished goods, and technical support.
Print3 : Could you tell us more about Zenith Rollers?
P.S.Paintal : Zenith Rubber commenced its roller manufacturing operations approximately 50 years ago, initially focusing on printing rollers and subsequently diversifying into sectors such as paper, steel, and textiles. We take pride in being the sole manufacturer in India that produces rollers for nearly all industries, providing roller covers made from rubber, polyurethane, and composite materials.
Notably, we are currently the exclusive producer of composite rollers, and for the past three years, we held the distinction of being the only manufacturer of polyurethane rollers until the recent entry of two new competitors in the market. Regarding the challenges we have encountered, we have certainly faced numerous obstacles. A significant challenge has been the ongoing necessity for upgrades, particularly in light of the emergence of newer, faster machinery and the demand for more advanced compounds.
Nevertheless, we have effectively addressed these challenges by investing in superior equipment, skilled personnel, and technological advancements to maintain our competitive edge.
“With total turnover experiencing phenomenal growth over the last five years Zenith has emerged as a multi-million dollar conglomerate and a world leader in the rubber roller industry”
P3 : What are your company’s principles, mission & vision?
PS : Our Mission is to keep delivering cutting-edge solutions of the highest quality with a customer-first mindset and to always remain at the zenith of innovation in this ever-evolving industry. And the Vision is to create competitive advantage for our clients by setting a benchmark for quality and become a name synonymous to rollers across the world.
P3 : What types of rollers does Zenith Rollers manufacture for the printing industry, and what are their primary applications?
PS : Zenith Rollers manufactures a wide range of industrial rollers for printing, packaging, and specialized industrial applications. The key categories include Offset Printing Rollers, Flexographic Rollers, Gravure Rollers, Industrial Rubber Rollers, PU Rollers, Silicone Rollers, Ceramic-Coated Rollers, and Lamination Rollers. Each roller type is designed for specific printing processes, ensuring optimal ink transfer, precision, and durability. The Offset Printing Rollers are particularly essential for newspaper, commercial, and packaging printing, where consistency in ink distribution and resilience to high-speed operations are critical.
P3 : What kind of rubbers are used in Zenith Rollers’ manufacturing, and how do they impact roller performance?
PS : Zenith Rollers employs high-quality materials, including EPDM, Nitrile (NBR), Neoprene, Polyurethane (PU), and Silicone rubber, chosen based on the printing process and environmental conditions. EPDM is widely used for offset printing due to its excellent resistance to heat, ozone, and UV exposure. Nitrile rubber is highly resistant to solvents and chemicals, making it ideal for gravure and flexographic applications. Neoprene offers a balance of chemical resistance and mechanical durability, making it suitable for general printing rollers. Polyurethane rollers are designed for high-speed applications where wear resistance is crucial. Silicone rollers, known for their extreme temperature resistance and non-stick properties, are used in heat transfer and specialty printing applications. These materials ensure that the rollers maintain precision, durability, and consistent performance under different operational conditions.
P3 : How does roller hardness affect print quality and machine efficiency in Zenith Rollers?
PS : Roller hardness is a crucial factor in determining the efficiency and quality of the printing process, directly impacting ink transfer, pressure distribution, and durability. Zenith Rollers manufactures rollers with different hardness levels, each tailored to specific printing requirements to optimize performance and extend roller lifespan.
If the incorrect roller hardness is used, it can lead to poor ink transfer, excessive dot gain, streaking, roller slippage, and reduced roller lifespan. By offering customized hardness levels for different printing applications, Zenith Rollers ensures that its rollers deliver superior print quality, reduced downtime, and maximum machine efficiency. Proper selection of roller hardness allows printers to achieve consistent color reproduction, minimize material waste, and optimize operational performance in diverse printing environments.
P3 : How does roller swelling impact printing accuracy at Zenith Rollers, and what measures can be taken to prevent it?
PS : Roller swelling occurs when solvents, inks, and cleaning agents penetrate the roller’s rubber compound, leading to dimensional changes that affect print accuracy. This can cause registration issues, uneven pressure distribution, and ink flooding, reducing print quality and increasing machine downtime. Zenith Rollers minimizes swelling by utilizing high-performance rubber formulations, such as solvent-resistant nitrile and polyurethane compounds, which withstand aggressive chemical exposure. Proper roller maintenance, including the use of recommended cleaning solvents and regular conditioning, helps prevent excessive swelling and extends the roller’s service life.
P3: What are the benefits of ceramic-coated rollers in high-speed printing at Zenith Rollers?
PS : Zenith Rollers manufactures ceramic-coated rollers, which offer high durability, improved ink metering, and enhanced thermal stability, making them ideal for high-speed printing operations. Ceramic coatings provide exceptional wear resistance, ensuring longer roller life and minimal maintenance requirements. These rollers exhibit precise ink control, reducing ink wastage and improving image sharpness. Additionally, their high thermal conductivity prevents overheating issues in offset and gravure printing presses, making them essential for high-volume, high-precision printing applications.
P3 : Why is roller concentricity important for high-speed printing machines at Zenith Rollers?
PS : Roller concentricity ensures that the roller rotates uniformly, preventing vibrations, misregistration, and uneven ink application. Poorly concentric rollers can cause excessive machine wear, inconsistent printing pressure, and ink skipping, leading to reduced efficiency.Zenith Rollers employs precision dynamic balancing and strict manufacturing tolerances to maintain roller concentricity, ensuring smooth operation, extended roller life, and superior print consistency in high-speed printing environments.
P3 : What are the best practices for roller maintenance in printing applications at Zenith Rollers?
PS : Proper roller maintenance is essential for extending roller life and maintaining print quality. Zenith Rollers recommends daily cleaning to remove ink residues, dust, and solvents that can degrade ink transfer efficiency. Using appropriate cleaning agents based on roller material prevents premature damage—EPDM rollers require water-based cleaners, while nitrile and polyurethane rollers should be cleaned with alcohol-based solvents. Proper roller storage in a cool, dry environment prevents warping and premature hardening. Additionally, periodic regrinding and recoating services help restore roller surface integrity, ensuring continued high performance.
P3 : How does Zenith Rollers customize rollers for different printing applications?
PS : Zenith Rollers provides customized solutions tailored to the specific requirements of different printing processes, ink types, and machine specifications. This includes custom diameter, core type, hardness level, surface coatings, and chemical-resistant formulations. By working closely with press manufacturers and printing companies, Zenith Rollers ensures that each roller is optimized for maximum efficiency, durability, and print quality.
P3 : What technological advancements has Zenith Rollers implemented in roller manufacturing?
PS : Zenith Rollers continuously invests in advanced polymer formulations, laser-engraved ceramic rollers, and nano-coatings, enhancing roller durability, ink transfer efficiency, and environmental sustainability. These innovations improve print accuracy, extend roller lifespan, and reduce downtime, making them essential for modern, high-performance printing operations.
P3 : Do you have any special rubber compound for UV inks?
PS : Yes. Zenith has launched its new compound – “SUPER COMBI” for UV Ink/Conventional Ink. Zenith R&D team has developed a new genre of rubber compound for printing rollers, the “Super Combi which has the same chemistry as that of original printing rollers manufactures. The rollers manufactured with this compound maintain dimensional and hardness stability for a longer span of lime.
P3 : What is Superflex rubber and what are its application?
PS : “SUPERFLEX” Next Generation Compound For Inking & Dampening Rollers. It has been successfully accepted in the market by our valued customers after its successful launch 6 years back. This compound which has been manufactured from German raw-material has been a success in the Domestic and well as International Market. The roller manufactured with this compound is now coming with 2 years warranty.
P3 : How does Zenith Rollers contribute to sustainability?
PS : Zenith Rollers follows eco-friendly manufacturing practices, including recyclable materials, solvent recovery systems, and energy-efficient production techniques, reducing its environmental footprint.
P3 : What is your expansion plans for the future?
PS : In the coming five years, we envision our company as a leader with significant expertise in technology, machinery, and human resources. We have diligently embraced new technologies, ensuring we remain aligned with the advanced machinery being introduced in the Indian market. Our ambition is to establish ourselves as one of the foremost manufacturers of rollers made from rubber, polyurethane, and composite materials.
Furthermore, we are exploring new avenues for growth. We are currently testing shoe press belt technology and are preparing to launch this innovation in the market. Additionally, we are planning to enter the field of laser engraving, with a dedicated team already in place for this initiative. Consequently, we anticipate several exciting developments ahead and are optimistic about achieving success in these endeavors.