Replika Press Private Limited

Replika has well-trained and experienced typesetting staff working for more than 15 years. They provide a cutting edge at all levels from processing straight text to complex mathematical, chemistry, medical, legal and professional publications.

We are specialists in mathematical & technical typesetting and the drawing of complex line art. We can undertake both design and copy editing based on your requirement. Your original data can be supplied to us in a variety of digital formats, which might include files output from an existing database, spreadsheet or word processing package, as well as handwritten copy or manuscripts. We have a complete library of licensed up-to-date software including; Quark XPress, PageMaker & InDesign. Your publication will be converted into suitable Internet-ready or Printable file formats including; HTML, PDF, SGML, XML.

To experience our typesetting quality we offer a free typesetting trial.  Send us 24 pages for your free typesetting trial of any given format. We’ll typeset to your specifications and upload the same within a week.

Replika has latest online infrastructure for Soft Cover, Hard Cover and Saddle Stitch Binding. Multiplex IN-Line System 24 Gathering stations featuring 24 SignaLynx camera system, connected to two Astronic 180 sewing machines complemented by strackers is the first in India, equally supported by new Stahl, Folding machines. We can produce

• 50,000  hard case books per day 
  
• 1,00,000 Soft cover books  per day

Folding Machines:

• Multi functions TH 82-4-4-2 + RCF + SBP 66
• Model StahI KH 78-4 KTLL+ FFH + SAK66
• MBO Combi-folding KC760 / 4KL –  2 Units
• Stahl Folder TF 78-4.4.4.2 Folder
• Stahl Folder KC 78/4 KTL + SBP 66
• Brehmer Mc Cain Folder with Round pile Feeder 4.4.4.2

Soft Cover Online Binding:

• Wohlenberg Sprinter 7010, 28 stations gathering with optic control. Attached online to Wohlenberg City e 6000 cycles/hr. Perfect Binder connected to Kolbus HD 140 Three Knife Trimmer
• Muller Martini – Baby Pony Binder

Saddle Stitcher:
Heidelberg Stitch Master ST-100 2003 model, 6 stations gatherer with cover-feeder, stitcher and three knife trimming machine. 

Hard Case Binding:

System Binder:
Kolbus KM470 27 clamps with end sheet pasting stations with online Sigloch Nipping station and hard case back lining station.

Case Maker:

• Kolbus Case Maker DA 260, 40 cycles/min with facilities of Flexi bind, Round corner, Flat back with 4 Parts, 5 Parts and eccentrics binding.
• Kolbus DA 36 Case Maker with viscosity control 
• Corner Cutting for DA 36

Board & Cloth Cutter:

• Kolbus Cloth Cutter
• Kolbus PK Board cutter 

 

Casing- In:

• Kolbus Hard Casing- In BF 527, FE 604 + DS 391 with preheating device and hot air blowers, connected online to Three Knife Trimmer Kolbus HD 143P. 
• Kolbus Jacketing  

 

Wiro Binding:

JBI 5000 James Burns Switzerland Wiro Binding & Punching machine.

 

Guillotines:

• Cutting System POLAR -RA4- 1 XT-T Computer – controlled and programmable, networking.
• Euro Cutter – 115 – 4 units
• Paper Reel Cutter 

Three Knife Trimmers

• Kolbus 3 knife trimmer HD 140
• SDY2 Perfecta Three Knife Trimmer

 

Finishing:

• Hot foil stamping/embossing & die cutting machines
• Kluge EHD size 18” x 24” 

 

Lamination:

• Semi automatic filming machine YFMI 920
• Thermal film – fully automatic lamination machine YFML- 920 

 

UV Varnish:

• Mini CAM-Shell, GF-1824 MCS for screen printing.
• 500 mm U.V. Curing / IR drier system 

 

Packing:

• Online thermal label printer and applicator
• Fully automatic shrink wrapping machine - 2 units
• Fully automatic carton packaging with flap folder and taping machine
• Fully automatic strapping machine.
• Automatic stretch wrapping machine for pallets

A team of highly dedicated professionals are responsible to handle the state- of- the- art equipment. Digital files with a varying degree of complexity are analysed to produce perfect images.

Hardware:

• Creo-Scitex Scanner
• CTP Dainippon Screen Thermal Plate Recorder with on-line processor/Model PT-R8600S  x 2 Units

•  
  •  Plate Size Max 45.6 x 37 inches Min 17.7 x 14.5 inches
  • 1200/2400/2438/2540 DPI resolution
  • Online Processor 
  • 22 Plates an hour

• Dolev 800 V Image Setter
• Epson Stylus Pro 7600 -24 inch width
• Epson Stylus Pro 9800 - 44 inch width
• Automatic Vertical Camera
• Plate Exposure Frames – 4 units
• Proteck Plate Processor
• Proteck Film Processo

Software:

• Preps - 4.1 Imposition Software
• Pixel Stream with Spectra Dot CIP – 4
• Compose Express RIP Software
• Brisque Workflow System
• EFI Colour Management System

Replika has several sheetfed offset presses from signal colour , two colour perfectors to five colour presses with IR drier , auto plate changer and CIP 4 facilities.

We can print:

• 1.2 million impressions per day on sheetfed
• 0.6 million impressions per day on perfector

Five - Colour:

• KBA Rapida – 105 Sheetfed offset printing machine with auto plate changer and auto blanket wash with IR drier, Grafix powder spray (Maximum sheet size: 1050mmx720mm)
• Heidelberg SM 74-5+L Sheetfed offset press with coater CPC 104-CP Tonic IR drier technotrans refrigeration unit, grafix powder spray, auto plate changer, auto blanket wash, preset feeder with CIP 4. (Maximum Sheet Size mm 720x520mm)

Four - Colour:

• Heidelberg Speedmaster CD 102-4, CP-2000, 4 colour Sheetfed offset press. 15000 impressions per hour with auto plate changer, auto blanket wash, IR drier with CIP 4.  Maximum Sheet Size: 1020mm x 720mm)

• Mitsubishi Sheetfed – Diamond 3000 with I-R Dryer, auto plate changer, auto blanket wash with CIP 3. (Maximum Sheet Size: 1020mm x 720mm)

• Heidelberg Sheetfed – SM 102 V - CPC – 102. (Maximum Sheet Size: 1020mm x 720mm)

Two - Colour:

• Heidelberg Speedmaster 102-2P, CPC 1-04, CP-Tonic Alcolor, Techotrans recirculation and refrigeration Grafix powder spray, auto plate changer with perfection, clamps, preset, steel plate in feeder.

• Heidelberg Sheetfed – 102 ZP with CPC remote controller registration and inking system, alcolor dampening, grafix powder spray. (Maximum Sheet Size: 1020mm x 740mm)

• Heidelberg Sheetfed – 102 ZP with CPC remote controller registration and inking system, alcolor dampening. (Maximum Sheet Size: 1020mm x 740mm)

• Roland Rekord  RZK 3B 1/1 Perfector. (Maximum Sheet Size: 1020mm x 720mm)

Single - Colour:

• Heidelberg Sheetfed – SORS with alcolor dampening – 2 Units. (Maximum Sheet Size: 1020mm x 740mm)
• Heidelberg Sheetfed – SORD – 2 Units. (Maximum Sheet Size: 915mm x 640mm)

Plans for 2010:

• To replace CPC 102 with new 4 colour or 4/4 colour Sheetfed with perfection.
• Digital Printing