ALU Technology
From raw foil to finished packaging — Monica International delivers excellence through advanced aluminium conversion, coating, printing, and finishing processes.
Step 1: Aluminium Rolling
Our aluminium processing begins with cold rolling of base aluminium sheets, starting at 0.6 mm thickness and gradually reduced to ultra-thin gauges ranging from 120 to 6.3 microns. These foil rolls, available in widths of 600 mm to 1800 mm, are designed for use across dairy, pharma, food, and container segments. The final output is either further processed in-house, sent to subsidiaries, or shipped to global converters.
Step 2: Basic Converting
Lacquering
We apply heat-seal lacquers and print primers using our multi-stage coating systems. All lacquers are developed in-house with a focus on water-based, eco-friendly formulations that ensure safety and compliance for sensitive applications.
Laminating
Aluminium foil is combined with other substrates such as film or paper to create strong, multi-layered laminates (e.g., alu/film, alu/paper/alu). These are widely used in confectionery, butter, and snack wraps. We support dry, wet, and wax lamination depending on the end-use and barrier needs.
Extrusion Coating
Using polymer extrusion, we apply tailored sealing layers on aluminium foil. Through co-extrusion technology, multiple polymer layers are combined in a single process to produce a “sandwich” structure, compatible with specific cup or tray materials for high-performance lidding applications.
Step 3: Printing
Rotogravure Printing
We offer high-resolution rotogravure printing with up to 10 colors, including options for reverse-side printing and inline treatments like cold-seal or lacquer. The engraved copper cylinders ensure sharp, consistent print quality for demanding branding applications.
UV-Flexo Printing
Using photopolymer plates and UV-curable, solvent-free inks, our UV flexo process offers photo-realistic quality, up to 8-color capacity. It’s ideal for eco-conscious brands seeking vibrant visuals with reduced environmental impact.
Flexographic Printing
This direct-pressure printing process is widely used for high-speed printing on foils, films, and papers. With up to 10 color stations and fast-drying inks, flexo printing is ideal for both short and long runs, offering cost-efficiency and clarity.
Digital Printing
Digital UV Inkjet printing allows for on-demand, short-run packaging with zero plate costs. Perfect for quick turnarounds, personalization, or smaller batches, digital printing offers unmatched flexibility and is increasingly favored in the pharmaceutical and specialty food segments.
Step 4: Converting & Finishing
Slitting
Foil master rolls are slit into precise widths and reel diameters to meet customer packaging line requirements — ensuring seamless integration and minimal waste.
Die Cutting
Customized lids and shapes are cut using stamp-and-die systems, with embossing or deep-draw options available. Standard shapes are readily available, and custom dies can be developed based on client requirements.
Deep Drawing
Aluminium containers are formed using pressure-based shaping from foil reels. This is ideal for food trays, butter containers, and portioned packaging. We offer standard sizes and customized molds.
Reel Cutting
Our high-speed reel cutters divide large rolls into narrower formats, adjusting for web width, core sizes, winding direction, and angle — ready for use in form-fill-seal machines or converter lines.
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