Flexible Packaging Technology in Sri Lanka
Through disciplined use of R&D, data, and advanced pre-press systems, we develop packaging solutions that improve efficiency, accuracy, and consistency. Our technology helps brands achieve dependable outcomes across design, production, and real-world application.
Every stage of the pack, made and proven in-house.
Varna operates the full flexible-packaging chain on one site in Ratmalana: in-house film extrusion, rotogravure and CI flexographic printing up to nine colours, solvent, solventless and water-based lamination, precision slitting, and pouch conversion across ten formats, all checked in an in-house laboratory. Nothing is handed off, so the structure never leaves our control.
- 3-layerIn-house co-extrusion, so the barrier is controlled at source
- 9 coloursRotogravure and CI flexo, with the full range of coatings
- 3 systemsSolvent, solventless and water-based lamination
- 10 formatsFrom reel form to retort, stand-up and vacuum pouches
- BRCGS + FSSCFood-safety certified, maintained through every audit
- 98.8%External acceptance rate at customer goods-inward
Six stages, one roof, one accountability.
Nothing reaches the line unchecked.
Quality starts before production does. Every incoming film, resin, ink and adhesive is checked against its specification and the supplier certificate, and held until it is released. Material that does not meet the standard never reaches a machine.
- What we checkFilms, resins, inks, adhesives and foils
- Checked againstSupplier certificate of analysis and in-house laboratory verification
- On arrivalHeld until inspected and released to production
- Inspection pointsIdentity, gauge, dimensions and appearance
Barrier built in, not bought in.
We extrude our own film in-house, so the barrier structure is controlled at source before a single colour is printed. Machinability and shelf life are solved up front, not discovered on your filling line.
- StructureUp to three-layer co-extrusion
- FilmBlown film, extruded in-house
- MaterialsLLDPE, LDPE, mLLDPE and HDPE
- Gauge range25 to 250 microns
- Maximum width1,390 mm
- Surface treatmentCorona treated to 42 dyne
- RecyclabilityMono-material structures, recyclable
Nine colours, matched to the order.
Rotogravure carries the large orders and CI flexographic the mid-size orders, both in-house and both up to nine colours, with the full range of coatings and finishes. Pre-press checks every file before a cylinder turns, so colour holds across repeat orders.
- ProcessesRotogravure and CI flexographic, both in-house
- ColoursUp to nine on both processes
- FinishesMatte varnish, high-gloss, soft-touch, cold seal and metallic
- Maximum print widthGravure 1,050 mm, flexo 1,000 mm
- Print repeatGravure 450 to 900 mm, flexo 300 to 750 mm
- RegistrationGravure ±0.1 mm, flexo ±0.05 mm
- Colour managementX-Rite spectrophotometer against the brand standard
- Cylinders and platesOutsourced, 95% colour match to the Cromalin proof
Rotogravure or flexographic, matched to your order.
| Consideration | Rotogravure | CI flexographic |
|---|---|---|
| Best suited to | Large orders | Mid-size orders |
| Colours | Up to nine | Up to nine |
| Finishes | Matte varnish, high-gloss, metallic | Matte varnish, cold seal |
| Changeover | Longer set-up, unmatched consistency at volume | Fast changeover, lower solvent and ink waste |
The right bond for the brief.
Three lamination systems, solvent, solventless and water-based, chosen to the structure rather than to the machine we happen to have free. Food-contact adhesives are standard, and retort-grade bonds hold through sterilisation.
- SystemsSolvent, solventless and water-based
- StructuresTwo to four ply, adhesive lamination
- SubstratesPET, BOPP, CPP, PE, nylon, foil and metallised films
- Retort adhesivesRated to 120 degrees Celsius
- Maximum width1,200 mm
Cut to size, wound to feed clean.
Finished reels slit to the width and diameter your line expects, wound for tension and traceability.
Infeed width
Webs 300 to 1,300 mm
Minimum slit
From 20 mm
Roll diameter
Up to 800 mm
Core sizes
96 mm and 180 mm
Ten formats, finished in-house.
Reel to finished pouch without a hand-off. Dedicated machines for stand-up, spout and flat-bottom formats sit alongside three-side, centre and quad seal, side-welded, PE bags, retort and vacuum, plus wet wipes, opening bags, soft-drink wrappers and bulk formats.
- FormatsReel, three-side, centre and quad seal, stand-up, flat-bottom, side-welded, PE bags, retort, vacuum
- Pouch size40 x 35 mm up to 1,020 x 560 mm
- Fill range10 g up to 25 kg
- FeaturesPress-to-close zippers, spouts, tear notches, round corners, euro-slot hang-holes, easy-peel reseal and hot-needle perforation on PE bags
- Retort capableSterilised at 121 degrees Celsius for 30 minutes
How reliability is engineered in
Solved before a roll is printed.
Our R&D is grounded in how packaging actually performs: on the filling line, in transit, and on the shelf. We develop structures that work in real production without forcing disruptive change.
- Barrier at source. Film is extruded in-house, so structure is controlled, not corrected later.
- Proven on the bench. A structure is validated before it goes to volume.
- Lighter and recyclable. Developed on brief, without trading away performance.
- One accountability. The team that specs it stands behind it on the line.
Caught on screen, not on press.
Strong pre-press foundations keep designs printing correctly, colours consistent, and production moving smoothly across materials, variants and repeat orders.
- Consistent colour output. Colours and branding stay uniform across every print order.
- Print-ready artwork. Files are refined for error-free, efficient production.
- Quality across materials. Designs are optimised for films, laminates, paper and foil.
- Early issue prevention. Print problems are identified before production, not on press.
- Consistent across variants. Accurate proofing and version control for SKU variations.
- Reliable at speed. Stable, precise results across high-speed printing lines.
Measured against the spec you signed off.
Every order is checked against its approved specification, order after order. Inline print inspection on the gravure and CI flexo presses compares each impression against the approved master and stops automatically at a defect for operator review. Batch and lot traceability runs end to end, proven by annual mock-recall exercises, with a certificate of analysis available on request. It is why the external acceptance rate holds at 98.8% at customer goods-inward.
- Seal and closure integrity
- Lamination bond and metal-bond strength
- Coefficient of friction for clean machine handling
- Barrier performance (oxygen and water-vapour)
- Hot tack and heat-seal performance
- Gelbo-flex and puncture durability
- Pinhole and opacity checks on foils and films
- Print and colour vs the brand standard, verified on X-Rite
- Leak testing by vacuum immersion
- Organoleptic odour evaluation
- Mechanical strength: tensile, puncture, drop
- Thermal and retort resistance
- Dimensional, gauge and GSM accuracy
- Residual-solvent verification via accredited external laboratories
Food safety you can audit.
Varna holds the BRC Global Standard for Packaging Materials at Grade A (Issue 7) and FSSC 22000 Version 6, maintained through every repeat audit, alongside an Environmental Protection Licence from the Central Environmental Authority. Food-safe inks and adhesives are used as standard, with no toluene, MEK or restricted heavy-metal pigments.
Where this chain shows up.
Product formats
The same converting chain, finished to the format your product needs.
Market sectors
Structures matched to how each sector fills, ships and sells.
Frequently asked
Does Varna offer both gravure and flexographic printing in Sri Lanka?
Yes. Varna offers rotogravure for large orders and CI flexographic printing for mid-size orders, both in-house and both up to nine colours, with the full range of coatings and finishes.
Does Varna make its own film?
Yes. In-house extrusion, up to three-layer co-extrusion, lets Varna control the barrier structure before printing begins, rather than relying on bought-in substrate.
What types of lamination does Varna offer?
Three systems: solvent, solventless and water-based, chosen to suit the structure. Food-contact adhesives are used as standard.
What certifications and quality standards does Varna hold?
Varna holds BRCGS Packaging Materials at Grade A and FSSC 22000 for food safety, maintained through every repeat audit, and holds a 98.8% external production acceptance rate.
What are Varna’s minimum order and lead times?
As a guide, minimum orders start from 20,000 pouches or 200 kg for reel form, with a typical lead time of 21 days from approved artwork and Cromalin proofs within 3 to 5 days. These figures are indicative, not fixed. The minimum order quantity depends on the material structure, product format, manufacturing process, printing method (printed or unprinted), machine selection, pouch size, film gauge, number of colours, and other process requirements, so it is evaluated on a case-by-case basis. Lead time varies with the product category, manufacturing process, artwork approval timeline, and whether the product is printed or unprinted, and different product categories require different manufacturing routes, so a single lead time may not reflect every case.
Tell us how the pack has to perform.
Send us the structure, barrier requirement, filling line and order size. Our team responds within one business day with a considered answer, not a sales pitch.
