Recycle your embossing sleeves in 5 days instead of waiting 5–8 weeks.
4P ReSleeve Pro™ helps tobacco & FMCG packaging teams keep launches on schedule while cutting sleeve tooling costs by up to 75% by reusing the aluminum sleeves you already own.
When a sleeve is late, everything is late.
If a launch has ever slipped because a new embossing sleeve didn’t arrive in time, you know the fallout:
Delayed launches and press schedules
Emergency tooling slots and rush fees
Budgets blown on “must-have” new sleeves
Perfectly good aluminum bodies scrapped for no reason
ReSleeve Pro™ gives you a smarter way to run your pressroom:
Instead of buying new sleeves, you recycle the ones you already own.
What ReSleeve Pro™ Does
Sleeve recycling that actually works in production
4P ReSleeve Pro™ is our sleeve recycling program for embossing sleeves used in tobacco and FMCG lines.
With ReSleeve Pro™ you:
✅ Cut lead time from 5–8 weeks for new sleeves to about 5 working days
✅ Reduce tooling costs by up to 75% per sleeve
✅ Reuse existing aluminum bodies instead of scrapping them
✅ Gain flexibility for frequent design changes and shifting formats
✅ Lower your environmental impact with less scrap and raw material demand
How ReSleeve Pro™ Works
From worn sleeve to press-ready tooling
We don’t just patch old sleeves. We rebuild them to production-ready quality.
Here’s how the process works:
.1️⃣ Old design removed
The worn engraving layer is fully stripped from the sleeve.
2️⃣ Clean & prepare
The aluminum body is cleaned and degreased for optimal adhesion.
3️⃣ New zinc layer applied
We rebuild the surface to the required specification.
4️⃣ Machined to final size
The sleeve is turned to precise final diameter and tolerances.
5️⃣ Engraved with new design
The new embossing design is engraved, often by laser for fine detail.
6️⃣ Finished & protected
Surfaces are sandblasted, inspected, and chrome coated so the sleeve is press-ready.
Same process steps and controls as new sleeves, just without the waste of a new aluminum body.
Sleeve Recycling vs. Buying New: What Makes More Sense?
Reusing your existing sleeves doesn’t just save time and money, it gives your team more flexibility, reduces environmental impact, and keeps production running smoothly.
Is ReSleeve Pro Right for You?
✅ You work with fast-changing designs and can’t afford long tooling delays
✅ You run tobacco or FMCG lines and need flexibility when formats shift
✅ You’re looking to reduce tooling costs without compromising print quality
✅ You already have sleeve bodies in good shape—but need a new engraving
✅ You’re tired of chasing emergency slots when sleeves are late
✅ You care about reducing waste and reusing aluminum instead of scrapping it
FAQs
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If your sleeve’s aluminum body is still structurally sound—with wall thickness above 15 mm—it’s very likely recyclable. We’ll assess each sleeve before starting to ensure it's a good fit.
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Recycled sleeves are typically ready within 5 working days—a huge improvement compared to the 5 to 8 weeks it takes to manufacture new sleeves.
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On average, tooling costs drop by up to 75% compared to buying a new sleeve. You’ll also save time, reduce waste, and avoid emergency tooling slots.
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ReSleeve Pro is designed specifically for embossing sleeves and similar tooling. We’ll confirm compatibility during the intake process.
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Yes. As long as the aluminum body remains in good condition and wall thickness allows, sleeves can be recycled multiple times.
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Not at all. We follow the same engraving and finishing steps used in new sleeves—including laser engraving, sandblasting, and chrome coating—to ensure top-tier quality.
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We can turn down oversized sleeves or build up smaller ones with zinc—within safe limits. This flexibility is especially useful when shifting formats or dealing with different press lines.