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Transcript of Modern Packaging & Design - July-August 2012
Mod
ern
Pa
cka
gin
g &
Desig
n
July-A
ug
ust 2
012
EDITORIAL
Editorial Advisory BoardP V Narayanan
Member of Board APEDA (Ministry of Commerce)
M K BanerjeeDirector-Creativity & Innovations (Global)
Essel Propack Ltd
R KrishnamurthyDirector-Marketing & Operations
Orient Press Ltd
S DasManaging Director
Nordson India Pvt Ltd
Manas R [email protected]
he developing economies of yesteryears are very much on the driver’s seat today and unequivocally defining the next growth phase of the world. At the same time, however, the global economic order seems to have shifted gears from the Brazil, Russia, India, China
and South Africa (BRICS) buoyancy to the Portugal, Ireland, Italy, Greece and Spain (PIIGS) spin. As the cloud of political and economic uncertainty remains far from clear over Greece, and hence, the European Union, followed by its projected ripple effect on the entire world, perhaps, the moment of truth has arrived to make some tough strategic decisions that will hold the business in good stead in the future.
Against this backdrop, here is a snapshot of the packaging sector as it has been shaping up recently at the global, regional and national level. Undoubtedly, the spotlight is on India, of late, in this category. According to a recent market report, the Indian packaging industry is on its way to becoming the fourth-largest packaging market in the world, with revenue to rise in excess of $ 43 billion by 2016. Given its consistent double-digit growth rate over the last few years as well as low per capita packaging consumption, this figure appears within reach.
While retail, pharmaceutical and processed food have been the major demand drivers for packaging over the recent years in both India and abroad, the domestic sector continues to be fairly fragmented. That said, the next phase of evolution in packaging is likely to witness greater demand for various sustainable products and practices, packaging as a more focussed tool for marketing and distribution, smart packaged products with state-of-the-art safety features, nanotechnology in food packaging and anti-counterfeiting devices, among others.
With such a dynamically evolving ecosystem, welcome to the 7th Anniversary Edition of Modern Packaging & Design! This edition extraordinaire delves deeper into the above and more such emerging avenues. Turn to the Anniversary Special section (with seven sub-sections, each representing a crucial cog in the packaging value chain) to discern what the experts have to opine, not just on the underlying trends and technologies, but also on the future prospects & pitfalls.
We believe that you will benefit from exploring this special edition as much as we have enjoyed ‘packaging’ together these highly informative pieces of actionable knowledge. Have a good read and looking forward to your valuable feedback. Cheers!
TSeven pearls of packaging
Modern Packaging & Design July-August 2012 5
Modern Packaging & Design July-August 2012 7
CONTENTS
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Special Focus: Plastic Packaging
Insight & Outlook: Caps & Closures
Anniversary Special
‘Pack’ing a punch with innovation
28 Design
36 Materials
44 Machinery
52 Logistics
60 Safety
68 Security
74 Sustainability
Insight & Outlook
82 Consumer-friendly packaging: Enhancing customers’ experience
Event Preview
�88� PackPlus South 2012: Emphasising on India’s packaging prowess
REGUL AR SECTIONSEditorial ................................. 5
News, Views & Analysis ...... 12
Technology & Innovation .... 18
Design Innovation ................ 20
Technology Transfer ............. 22
Projects ................................. 84
Tenders ................................. 85
Event List............................. 86
Book Review ........................ 90
Products ................................ 93
List of Products.................... 99
List of Advertisers .............. 100
Cover illustration and design: Chaitanya Dinesh Surpur and Sharad Bharekar
Highlights of Next Edition
In Conversation With 24 Ajit Singh, Chairman, ACG Worldwide
Facility Visit 80 Uflex Engineering Ltd: Pioneering
innovations in f lexible packaging
Details on page no.86
FOUNDER & EDITOR, NETWORK 18Raghav Bahl
PRESIDENT & EDITORIAL DIRECTOR, TV 18Senthil Chengalvarayan
SENIOR EDITORManas R Bastia
EDITORIAL TEAMAnnabel Dsouza, Swati Sharma, Lionel Alva, Hemantraj Ratnakumar,
Anwesh Koley (Delhi), Avani Jain (Ahmedabad)ASSISTANT ART DIRECTOR
Varuna Naik
DESIGNSharad Bharekar
CHIEF PHOTOGRAPHERMexy Xavier
PHOTOGRAPHYNeha Mithbawkar, Joshua Navalkar
BUSINESS CONTROLLERSLovey Fernandes, Akshata Rane, Surekha Karmarkar, Deepak Bhatia,
Ashish Kukreti, Shwetha ME, Jayashree N, Sugandha Kulkarni, Shefali Mahant
PRINTINGEXECUTIVE VICE PRESIDENT
Ananth R Iyer
ASSISTANT GENERAL MANAGER - PPCShekhar Khot
PRODUCTION TEAMDnyaneshwar Goythale, Ravikumar Potdar, Ravi Salian, Sanjay Shelar
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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd.Senior Editor: Manas R BastiaPrinted at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Packaging & Design is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 27106. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
Modern Packaging & Design July-August 2012 9
10 Modern Packaging & Design July-August 2012
GUEST EDITORIAL: Ashok Goel
Indian packaging industry is at an inflection point
The packaging industry plays a unique role by way of value creation
through manufacturing activities and preservation of the integrity
of packaged products. It reflects the society’s economic progress.
We have come a long way in packaging innovation, from using
leaves and terracotta pots to films with radio-frequency identification for
packaging foods or bottles in different shapes and sizes made of different
materials. In terms of innovation, the Indian packaging industry is at an
inflection point today due to the quality consciousness of the consumers
complemented by the increased awareness of hygiene & health and growth
of modern retail. But, here, it is primarily driven towards cost innovation
because of high commodity prices, reiterating our focus on value for money
and buying power per unit. We in India are geared to innovation in process
and products, keeping the functionality intact. The Indian packaging
machinery sector is fast catching up on innovations and is being influenced
by requirements within India rather than on a global level.
Globally, the economic condition is in a challenging phase, with developing
nations developing at lower growth rates and investments shrinking in new
capacities. In this scenario, the Indian packaging industry should try to push
the efficiency graph upwards through scrap reduction, increasing throughput,
improving supply chain efficiencies and using new and cheaper materials.
There is still much to do on the sustainability front, but the disjointed
actions of the concerned authorities and their knee jerk reactions are defeating
the purpose of growth. Plastics constitute the majority share in packaging,
and it is looked upon as a threat to the environment. But, in reality, it has
actually helped in conservation of natural resources such as paper, glass
and metal for packaging. Another advantage of plastics is that it is easily
reprocessed and recycled umpteen times. So, the real challenge lies in waste
management, which must start with waste segregation at source, making easy
and effective recycling, in order to address the sustainability issue successfully.
With the demographic changes, packaging revolution in India has started
and soon Indian packaging will make a mark on the world canvas.
Ashok Goel, Vice Chairman and Managing Director, Essel Propack Ltd
GUEST EDITORIAL: Ani l Sharma
Modern Packaging & Design July-August 2012 11
Packaging is in the driver’s seat of India’s growth story
Changing lifestyle, high disposable income and a more organised
retail is driving consumerism and positioning packaging to the
driver’s seat in India’s growth story. All these have enhanced the
buying experience of the Indian consumer. Not only has this
benefitted the Indian economy by preserving the quality and lengthening
the shelf-life of innumerable products, but also influenced the shelf appeal,
creating a new wave in the widespread adoption of product branding. Brand
owners are looking at packaging as a differentiation tool, which helps their
products to stand out in the competitive marketplace.
The Indian packaging industry has evolved significantly over the last
two decades. The market has witnessed the sachet revolution, unique to
emerging markets. Companies have leveraged local industries in paper, films
and plastic resins to create new solutions. Technology adoption has been
fast and new ideas are being experimented with everyday. For example,
decoration of product packaging has evolved from wet glue to self-adhesive
pressure-sensitive technology on automatic lines, improving aesthetics,
operating efficiencies and durability. The industry has made considerable
progress in materials, adopting cutting-edge printing & dispensing
solutions and localising packaging equipment at competitive price and
performance points, thus providing excellent packaging solutions to
enhance brand visibility.
The future is bright for the Indian packaging industry. Fundamentals are
in favour of India, with a buoyant youth populace, rising incomes, changing
lifestyle and an emerging middle class. The outlook is optimistic and the
industry is positive of emerging even stronger. The companies are now
tougher and have learnt from the previous setbacks during the slowdown.
They are more focussed and driving harder on innovations and efficiencies in
times of caution. This augurs well for the industry and is helping companies
compete in the domestic market and expand their forte beyond India & into
other markets.
Anil Sharma, Managing Director, Materials South Asia, Avery Dennison
GUEST EDITORIAL: Ani l Sharma
Modern Packaging & Design July-August 2012 11
NEWS, VIEWS & ANALYSIS
12 Modern Packaging & Design July-August 2012
Mamata Machinery on an expansion drive
Gujarat-based Mamata Machinery Pvt
Ltd is on an expansion drive. In order to
increase its production, the company is
shifting its operations from the present
facility in Vatva to a new facility in
Changodar in Ahmedabad, Gujarat.
The new facility has a total land area of
36,000 sq m and is much larger than the
previous one. Abhijit Deshmukh, Senior
Sales Manager, Mamata Machinery Pvt
Ltd, informed, “The new facility will
be completely operational in few weeks.
The major reason behind this shifting
of operations to a new facility was
the small size of the previous facility
and its inability to handle large-scale
productions.”
Further, at Plastindia 2012, the
company had launched Vega 1200 Split
– a dual-draw roll plastic bag maker.
With this technology, one can process
two printed bags of two different sizes at
a time, thereby doubling the production
but at a reduced cost. At the event, the
company had also showcased the shaped
stand-up pouches, ie, Vega 610, for the
first time in India.
Avani Jain
COMPACK 2012 explores sustainability efforts The Comprehensive Packaging Expo
(COMPACK) 2012, to be held in
Chennai during July 13-15, 2012, will
act as a platform for manufacturers of
packaging & printing machines and raw
materials providers to meet, while gaining
insights into the trends in the packaging
industry. The third edition of the
comprehensive packaging expo is expected
to garner an even greater response than
the previous exhibitions. The event has
great significance at the national and
international level, boosting the domestic
packaging industry.
The focus of the exhibition will be
on plastic waste management by creating
a better cognisance and urging the
packaging industry to be more responsible
towards the environment & consumer
safety. COMPACK 2012 aims to bring
a better regulatory framework for the
management of plastic waste generated
from packaging by attempting to bring
forth a consensus within the industry and
Government circles.
Lionel Alva
Heidelberg and Landa enter global strategic partnership
Heidelberger Druckmaschinen AG
(Heidelberg), Germany, and Landa
Corporation of Rehovot, Israel, have
entered a global strategic partnership for
the development of Nanographic Printing™
presses in order to expand digital
offerings for mainstream printing, eg,
short-to-medium runs, variable data and
quick turnaround printing. Heidelberg
intends to develop, manufacture, sell and
service new-generation digital printing
presses based on Landa Nanographic
Printing™ technology.
Benny Landa, Founder, Chairman
and Chief Executive Officer,
Landa Corporation, said, “The
Heidelberg-Landa alliance is a major
step towards achieving our strategic goal
of industry-wide adoption of nanography
for mainstream digital printing. As a
market leader, Heidelberg’s adoption
of Landa Nanographic Printing for
its new-generation digital presses is
a clear message to the entire market:
In foreseeable future, offset and
digital will not only co-exist, but will
complement one another – offset for
medium-to-longer jobs and digital for
short-to-medium run lengths, not to
mention variable data printing. Finally,
there is a digital printing technology
with speed and customer economics to
fill that role – and Heidelberg is certainly
well-positioned to take it to market.”
Anwesh Koley
BOBST launches advanced printing press for flexible packaging at Drupa 2012BOBST unveiled a wide range
of trailblazing innovations at
Drupa 2012. Among these is the
new Fischer & Krecke 20SIX CS
flexo printing machine. This is
an advanced Central Impression
(CI) flexo printing press for
flexible packaging. Avra Mitra,
Senior Manager-Key Accounts,
Business Unit-Web Fed, Bobst
India Pvt Ltd, commented, “The
machine has received a good
response at the event. It took us
almost two years to develop this
machine, which is an evolution
of the acclaimed Fischer & Krecke
FP 16 S and upgraded to include
improvements in printing quality,
ease of use and versatility. This is
the most compact press available
in its category and has the lowest
wavelength from the unwinder
to rewinder.”
He elaborated, “This machine
enables highest printing speed
even with the most demanding
jobs. It is also user-friendly and
requires less maintenance. Further,
with the incorporation of latest
patented technology Smart Graphic
Positioning System 2, the start-
up material wastage is reduced.
Another patented feature, ie, Smart
COL, helps the convertor to carry
out shade matching offline as well.”
Avani Jain
Benny Landa
NEWS, VIEWS & ANALYSIS
14 Modern Packaging & Design July-August 2012
Automated Packaging Systems focusses on Asia Automated Packaging Systems, the world leader in high-reliability bag packaging systems, has established a new regional headquarters in Bangkok, Thailand. This headquarters for Automated Packaging Systems Southeast Asia will provide comprehensive sales and service support for customers in countries that are part of the Association of Southeast
Asian Nations (ASEAN), including Thailand, Indonesia, Singapore, Malaysia, Philippines, Vietnam and Cambodia.
The new office will have access to the company’s full line of bag packaging systems and materials to provide streamlined packaging solutions for customers in various industries, including food, automotive, electronics, hardware, plumbing, commercial
parts manufacturing and e-commerce fulfillment. “We are committed to delivering high-quality bag packaging products and services to this region, where manufacturing and distribution are growing. We have experienced professionals in the new office to provide our customers with world-class assistance,” said Cliff Brehm, President and Chief Operating Officer, Automated Packaging Systems.
Borouge awarded for innovative sustainable solutions
RG 4 6 8 M O , a
Polypropylene (PP)
random copolymer
produced by Borouge,
bagged the Green
Material Award for
Innovation Application
in recognition of
its contribution to
the development of
packaging industry.
The recognition was
made during the 2012 China Plastics Industry
Awards ceremony. James Ong, Marketing
Manager-Moulding, Borouge, informed,
“RG468MO is the result of a product that was
developed with the customer’s needs in mind
to address the energy shortage in China. This
high-flow PP resin grade has enabled our
value chains to generate higher productivity
yield while lowering their energy consumption.
RG468MO represents a step-change in rigid
packaging material, without compromising
performance or aesthetics.”
The benefits of such proprietary Borealis
Nucleation Technology (BNT) comes with
improved mechanical performance allowing
faster and better crystallisation of PP,
which boosts the productivity cycle time by
20 per cent, yet maintains a consistency in
transparency and visual aesthetics required in the
packaging value chain. Ong added, “The Award
recognises and reinforces our continued effort
in advancing sustainability development across
value chains, ensuring that our products are
used appropriately throughout their lifecycle.”
Avani Jain
Innovative packaging solutions from LINPACLINPAC Packaging
has developed a range
of smart packaging
solutions to combat
food bacteria and help
consumers & retailers
reduce food wastage. The
leading food packaging
company, which caters
to the bakery, fresh
produce, fast food and
meat, fish & poultry
sectors, has partnered
with several supplier companies to develop
antimicrobial tray & film solutions in order
to reduce spoilage and increase the shelf-life
of food by inhibiting the growth of bacteria,
moulds & yeast.
The antimicrobial technology reduces
the risk of contamination from pathogens
such as Escherichia coli, Salmonella, Listeria
and Campylobacter – the most common
cause of food poisoning and the focus of
much debate within the food industry.
Alan Davey, Director–Innovation,
LINPAC Packaging, said, “While correct
handling and preparation of food prevents
bacterial contamination, the antimicrobial
technology is another safeguard to control
and significantly reduce the risk of bacterial
contamination.” Using food-safe, proven
biocides, LINPAC has developed its new
range of trays and films using additives
that can be applied in many ways according
to customer requirements and the food
to be packed. Another option is to apply
antimicrobial varnishes to films and trays
post processing.
Plastiblends adds appeal to colour masterbatches Plastiblends India Ltd (PBI)
has recently made significant
strides in colour masterbatches
for the packaging industry. The
new colour masterbatches have
an iridescent effect, which is
an important innovation for
packaging manufacturers.
“This will capture the
attention of packaging
manufacturers in the retail space
since this market is driven by
aesthetics. With the utilisation
of colour masterbatches with
the iridescent effect it will
be possible to create more
visually appealing products at
almost no extra cost. It will
also help brands to acquire a
distinguished presence on the
retail shelves and we foresee
tremendous demand for this
product,” averred Ashish
Kothavade, Senior Manager-
Business Developments, PBI.
Plastiblends has developed
antimicrobial masterbatches,
Ultraviolet (UV) inhibitors for
polyster films and UV stabilisers
since light permeation is an
important aspect of packaging
today. UVA slows down
the degradation process by
preferentially absorbing harmful
UV radiation and dissipating it
as thermal energy.
Lionel Alva
Alan Davey
James Ong
NEWS, VIEWS & ANALYSIS
16 Modern Packaging & Design July-August 2012
Asia’s middle class drives BOPP film markets According to a latest report on the global
Biaxially Oriented Polypropylene (BOPP)
film market from AMI Consulting, the
BOPP film industry continued to show robust
growth during 2011, with demand advancing
by 5.5 per cent as compared with that in
2010 to top 6 million tonne for the first time.
Global demand for this is increasingly driven
by developments in Asia, particularly China,
India and Indonesia.
With over 60 per cent of BOPP usage
happening in food packaging, the growth
in demand in these countries for an ever-
widening variety of packaged foods sold
through supermarket outlets is one of the
principal drivers for this material. With
large, youthful and expanding populations;
increased urbanisation; and rising incomes,
it is the developing markets of Asia that
will continue to drive growth in BOPP
film demand.
AMI believes that the BOPP film market
has the potential to continue growing at a
strong rate of 6-7 per cent per year over the
next five years. This would add another 2.3
million tonne of demand. As seen in 2011,
the strongest growth is likely to continue
in India, driven by development of the
organised retail sector opening up to foreign
investment.
ACTEGA’s innovation breaks new ground at trade show
At the recently held ‘World of Private
Label’ trade fair in Amsterdam, ACTEGA
DS, a new entrant to the fair, was
selected for the New Product Expo for its
innovative twist-off cap that features the
PROVALIN® compound without Polyvinyl
Chloride (PVC) and plasticisers developed
& patented by the company. Based on
advanced Thermoplastic Elastomers (TPE)
technology, this compound is processed by
the company’s development partner Pano in
its PANO Blueseal powered by PROVALIN®
metal seals.
The compound is available for use in
different methods such as pasteurisation,
sterilisation and cold-filling processes. It is
also available for a wide variety of lid sizes
and closures such as Twist-Off, Bandguard
and P/T, and hence for all kinds of glass jars
used in the food industry.
‘World of Private Label’ is a renowned
annual trade show that exhibits innovations
by leading international retailers. Product
innovations distinguished in terms of
innovative value, ingredients, packaging or
concept are presented at the event.
Atlantic Zeiser showcases new AIDC software at ACHEMAThe Atlantic Zeiser Group,
a leading developer and
provider of modules &
integrated total solution
systems for industrial
and security printing has
introduced its new software
Personalization Management
Platform (PMP) for track &
trace and anticounterfeiting
solutions at ACHEMA.
PMP can control the entire
production, identification
and dispatch processes of
packages for pharma products
by using interfaces to access
relevant data on all levels
of a production system. It
makes them available as
required in real-time during
the individual process stages.
PMP can be embedded into
adjacent and higher-level
software systems such as
Manufacturing Execution
System (MES) and
Enterprise Resource Planning
(ERP), or even used as an
MES itself. In addition to the
universal control of different
production levels, PMP Track
& Trace offers individual
reports and audit functions as
well as an integrated random
number generator for unique
product ID codes.
At ACHEMA, the
company also exhibited other
applications for the software
platform in the pharma
industry. This is significant
because product tracking
and authentication and real-
time checking are critical
components of comprehensive
anticounterfeiting solutions
for the pharma industry.
Manjushree’s exports to double with rising overseas demand for PETManjushree Technopack
Ltd, one of India’s leading
rigid plastics packaging
manufacturers, expects to
double its exports for this fiscal
2012-13. The growth in the
international earnings comes in
the wake of increasing demand
for Polyethylene Terephthalate
(PET) preforms from the
developed and developing
countries.
“We witnessed a 100 per
cent increase in our exports last
year, and we expect it to double this year
as well, with a growing interest for PET
preforms from the US, South
& West Africa and Thailand.
Our strong focus on innovation
has seen us introduce new designs
such as short-neck preforms,
and we expect significant demand
for such designs, particularly
from the beverage segment.
We hope to close next year’s
earnings at over ` 400 crore
from the current ` 300-crore
turnover,” said Vimal Kedia,
Managing Director, Manjushree
Technopack Ltd. Vimal Kedia
TECHNOLOGY & INNOVATION
18 Modern Packaging & Design July-August 2012
Nicholl adds smoothwall variants to foil tray range Nicholl Food Packaging has expanded
its range of aluminium foil trays
for the fresh and convenience food
sector by adding five new smoothwall
variants. Smoothwall trays feature a
smooth rim, which allows each tray
to be hermetically heat-sealed with
standard film on high-speed machines.
For extended shelf-life, gas flushing
techniques are incorporated into filling
and sealing phases of food production.
The trays offer a robust, heavy-duty
construction, reducing the weight of
sleeves and cartons and total pack costs.
These combine a quality, attractive
appearance with user-friendly benefits,
eg, easy handling, leak-proof seals and
shatterproof when frozen, and retain
their strength & rigidity at high oven
& grill temperatures. Smoothwall
trays are suitable for various product
types, eg, ready-to-cook meat, poultry
and fish, ready meals, barbecue
products, vegetables, etc. The trays
are available in rectangular and round
shapes with different depths & design
enhancements, eg, ribbed sides &
embossed squares on the base.
Bosch launches SurePOUCH pack stylesBosch Packaging Technology has
launched SurePOUCH – reclosable,
flexible pouches with a wide range
of applications from retail to food
service. The packs are filled on the new
SurePOUCH Clean-fill machine series
(SPC) and roll-fed Vertical Form-Fill-
Seal (VFFS) machines with a small
footprint of 6 sq m. The pouch formats
‘retail’ for retail sales and ‘food service’
have filling volume size in the range of
100 ml to 5 litre.
The SPC can produce four different
pouch formats. The formats EZPouch,
EZGable and EZSquare, with filling
volumes from 100 ml to 5 litre, offer
flexible applications for retail. For food
service, the EZPillow can hold up to
20 litre, allowing for easy and quick
refilling. All formats are produced, filled
and sealed with the same machine.
In addition to the SPC machine,
Bosch supplies both spouts and the
light-weight film or laminate structures
for the SurePOUCH packs, guaranteeing
seal and package integrity while ensuring
easy handling, storage & dispensing
of products. Due to its stable design,
the package still stands up once vacant.
Made from flexible materials, it allows
high evacuation rates for increased
utility as well as collapsibility for
efficient disposal. The new flexible pack
style also helps lower the product-to-
package weight ratio as compared
to rigid alternatives.
GCS launches new light-weight dispensing closure for tubes
Zeller Plastik France has launched
Touareg, a new light-weight 35 mm
diameter snap-hinged dispensing closure
for tubes to complete the Zeller standard
range from 30-mm to 50-mm tubes in
the Supersoft family range. Designed
to maximise cost reduction and reduce
environmental impact in line with the
GCS Cap Green sustainability initiative,
weighing just 4 gm, the closure is
20 per cent lighter than the previous
version, which leads to a substantial
reduction in carbon footprint. The
weight optimisation and sophisticated
high-cavity mould design enable
the company to offer the closure at
competitive price points.
Manufactured with Zeller Plastik-
originated and renowned butterfly hinge
technology, the closure suits the ND20.6
tube neck finish and is available in 2 mm,
3 mm and 5 mm orifice diameters. The
contemporary, trendy in design closure
comes in a wide range of matt colours
and the flip-top can be embossed to suit
customer requirements.
Epson announces seven-colour SurePress L-4033AWEpson has launched SurePress
L-4033AW – a seven-colour, inkjet
digital label press with white ink that
makes high-quality, short-run label
printing easier and more efficient,
even on clear & metallic substrates.
Delivering exceptional print quality
and accurate colour reproduction on a
variety of standard label substrates, the
machine enables label converters and
commercial printers to expand their
service offering & improve profitability.
In order to give a wide colour gamut
for precise colour matching and accurate
reproduction of spot/speciality colours,
Epson’s SurePress AQ ink-set includes
green & orange inks. The difference
is especially noticeable in the bright
green-to-yellow and yellow-orange-red
portions of the colour space, with higher
colour saturation and lifelike shades that
make labels more eye-catching. The
ink-set now includes white ink for solid,
opaque white printing on materials such
as clear film and metallic substrates.
The machine streamlines the
production processes of label converters
and commercial printers, ie, the machine
is quick & easy to set up, with no plates
or films to prepare. It also maximises
uptime with automated print-head
maintenance and hot-swappable ink
cartridges, with no need to stop the
press to change them during production.
DESIGN INNOVATION
20 Modern Packaging & Design July-August 2012
Weightless PET bottle The German Packaging Institute has now chosen the concept of
‘PET lite 6.6’, a 500-ml bottle developed using Krones’ NitroPouch
process for the German Packaging Prize. This new bottle made from
6.6 gm of Polyethylene Terephthalate (PET) constitutes a milestone
in the field of light-weight beverage containers.
The NitroPouch concept, as the primary package, minimises
material and energy consumption. The mouthpiece specially developed
for this bottle dispenses with the otherwise customary neck ring, and
weighs only 1.3 gm; the closure is as lightweight as 1.1 gm. Nitrogen
is used to build up a defined pressure inside the bottle, so that it does
not collapse during transport and handling.
Manufacturer: Krones
In a sea of look-alikes, the challenge is to bring to the market new and improved product concepts where the packaging does more than simply contain and protect the contents. Packaging innovation is crucial to the future of packaged goods, with user convenience being a key driver. As smart packaging concepts are predicted to be commonplace features in the future, this column is a tribute to the latest innovations in packaging designs.
Airless bottle with dual wall Sunrise Pumps has introduced a new series of stylish
dual-wall airless bottle ‘DA’. Developed by Sunrise, the
30-ml and 50-ml bottles feature a dual wall – the white
plastic inner wall can be seen through the transparent
outer one, providing two surfaces for decoration and
branding.
Made of styrene acrylonitrile, the opaque wall on
the bottle offers a prestigious look that is perfect for
upgrading an existing brand image, while the protective
polypropylene inner bottle ensures perfect compatibility
with all kinds of formula. In addition, the airless system
reduces residual ingredients and ensures hygiene.
Manufacturer: Sunrise Pumps
A glass of wineAn entirely new packaging
approach for wines that originated
in France is now possible in
plastics. The concept is finding
favour with sophisticated wine
makers who see new market
opportunities for wine served
in recreational and outdoor
venues. Wine is bottled into a
single-serve barrier plastic wine
glass with a shelf life of one
year. This saves 50 per cent of
packaging waste.
A significant technical
challenge was to overcome in
sealing of the lidding to the wine
glass rim without spilling the
wine. This innovation facilitates
the entry of wine in the ready-to-
drink beverage category.
Manufacturer: Copa Di Vino
DESIGN INNOVATION
Modern Packaging & Design July-August 2012 21
Innovative aluminium packaging
Exal Corporation’s new Coil to Can (C2C) aluminium
bottle manufacturing technology, for the first time,
features recyclable aluminium alloy and allows marketers
to consider aluminium bottles for large-scale beverage
applications.
C2C aluminium bottles use less material and are
manufactured at faster speeds to enable a 40 per cent
weight reduction at a cost comparable to Polyethylene
Terephthalate (PET) and/or glass. Apart from the
benefits of the materials used, the design of the bottles
ensures easy grip and ergonomic dispensing options.
Manufacturer: Exal Corporation
A refreshing design Procter & Gamble (P&G) has revitalised an iconic brand
through innovative new packaging. The new Scope Outlast
mouthwash from P&G has been developed with Alpla,
Tech Group and Webb deVlam Industrial Designers from
USA. Dubbed as the ‘Genie’ bottle, the new design has
outstanding stopping power and clearly separates Scope
from private label and other offerings in the category.
The new design of the Scope bottle has an additional
benefit of significantly reducing packaging materials as
PET usage was reduced by 20 per cent and allowing for
higher efficiency when shipping.
Manufacturer: P&G
Keeping it fresh and hygienic Cryovac has introduced
easy-to-open new design
for fresh and processed
meat & cheese, which yields
improved convenience, safety
and less waste of food. The
packaging is not only lighter
than conventional options,
but also ensures ease of
operation for the customer.
The Cryovac Grip
and Tear® bag combines the superior shrink, toughness and
oxygen barrier properties of a conventional vacuum shrink
bag along with an easy-open feature. A user simply grips the
package and tears it open. Easily opened by pulling a tab,
the bag’s knifeless design improves employee safety, reduces
the risk of cross-contamination, eliminates mess and keeps
the workspace clean.
Manufacturer: Cryovac
TECHNOLOGY TRANSFER
22 Modern Packaging & Design July-August 2012
Technology Offered
Air bubble packaging film A Korean company is offering its existing plant manufacturing
air bubble film. This plant (model: YS1200, YS1000, YS1400)
is equipped with modern facilities in accordance with excellent
quality production. The consumption of air bubble sheet is a
profitable business due to increasing demand in India.
Areas of applicationPackaging industry: It can also be used for agricultural applications
instead of LDPE where additional thermal insulation is required.
Forms of transferEquipment supply, turnkey
Bar code generating and printing A Thailand-based firm seeks to offer their services in bar
code generation and printing. They use highly professional
methods and their expertise will be useful depending on clients’
requirements. Other than consultancy, they provide training for
barcode generation, which would help the manufacturer improve
its prospects in the long term.
Areas of applicationPrinting industry, bar code auto ID section
Forms of transferConsultancy, turnkey
Coir Atlas An Indian firm is offering a green innovative technology – Coir
Atlas. It is an eco-friendly and biodegradable substitute of wooden
logs used by steel industry for shipment of flat products viz
sheets/plates and coils.
Areas of applicationPackaging and transportation
Forms of transferJoint venture, technology licensing
Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and �������� ���� ��� ���� �� � � ��������� �������� � � ����� ��������������� ��� ������� ���������� ��� ����� ��� ��� �������� ����������������� �!������� �"#�� %!��'� *����!������ ����� �+� /���� 33;� ;3<����=�;33">;?F�>FQX��/�������;33">;?F�>F3;����������Z�[=�;33� "�#<XQ�<#F\�������=�����]��������]�^!_�����`'���=�+++_�q���_����
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Adhesives, specialty additives and their intermediates A leading UK-based company is seeking innovative
investment opportunities in organic chemistry, chemical
formulations or processes including manufacturing,
technology licensing, acquisition, joint venture and
distribution. The company has a reputation for technical
innovation in high-quality performance products.
The company seeks to acquire rights to novel chemistry
products, innovative technologies, formulations,
compounds and applications that are in synergy
with its current range of activities, and that will increase
the diversity of its manufacturing base. Patents or know-how
would be desirable.
Areas of applicationPlastics rigid and flexible packaging, laminate printing and
processing, etc
Forms of transferManufacturing, technology licensing, acquisition, joint
venture and distribution
Recycled PET bottle machineryA Poland-based company specialising in recycled
PET polyester polyols manufacturing is looking for an
alternative proposal of design and engineering of bigger (about
25 ktpa) production plant. It plans to start with good quality
recycled PET flakes, which will be delivered in big bags.
Hence, the company requires a complete package offer for
this service.
Areas of applicationBeverage packaging industry
Forms of transferOthers
Share and Solicit TechnologyThe mission of Modern Packaging & Design is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology ��� ���������������z!�����_�* ���!�'����������� ������+������������
you are invited to furnish the techno-commercial details for publication. ���+���"!q�������'����q����� ������� ������������+����� ��������
�'�!�����q�����!�������������� �������z!��������������� ��qq��������and forms of transfer.
Contact: Modern Packaging & Design* ������3X�}����~���`�����!'����!���������+���������/������`��
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Technology Requested
IN CONVERSATION WITH: A j i t S ingh
24 Modern Packaging & Design July-August 2012
…emphasises Ajit Singh, Chairman, ACG Worldwide. Having served at the boards of several national and international associations for the pharmaceutical industry such as the Organisation of Pharmaceutical Producers of India (OPPI) and International Society for Pharmaceutical Engineering (ISPE), Singh highlights the need for research & development and innovations in India’s pharma packaging sector. A rare and exclusive interaction with Annabel Dsouza…
introducing innovation is strong
The key to
R&D
Photo: Mexy Xavier
Modern Packaging & Design July-August 2012 25
How has the pharma packaging sector evolved in India over the years?The overall view of the pharma packaging
and machinery industry is positive.
Today, packaging is not just looked at
as an aesthetic requirement, but also as
a necessity for customer safety, brand
protection and brand-building. Indian
companies have matured to become
complete solution providers with
machines for tableting, encapsulation,
coating, material handling for solid dosage
manufacturing, blister packing, cartoning,
pouch packing, case packing solutions for
packaging and check-weigher as well as
vision systems for online inspection.
To what extent does packaging contribute towards delivering world-class solutions to the Indian pharma industry?The consistently upward trend of the
Indian pharma industry has resulted in a
strong and steady packaging sector over
the years. Globally, India ranks third in
terms of manufacturing pharma products
by volume, and this gives immense
opportunity to Indian equipment
manufacturers, thereby expanding their
horizons. With innovations being a crucial
aspect in pharma packaging, companies
like ACG have been successful in dealing
with counterfeiting to a great extent.
By employing innovative technologies
such as Two-Dimensional (2D) coding
& Radio-Frequency Identification
(RFID), the packaging sector has helped
pharma and non-pharma companies
to protect their brand identity and
ensure customer safety.
How is the uncertain global economic climate impacting the pharma industry in India?The industry has shown a mixed
response to the economic slowdown.
Many projects in Europe and US have
been put on hold and that has inertly
affected our exports to those markets.
Nevertheless, there is a faint silver
lining as European companies, who
purchased only European machinery, are
now considering Indian manufacturers
having global standards with competitive
pricing edge.
What is your opinion on the competency of Indian companies as against their global counterparts?India is the world’s fourth largest
manufacturer of pharmaceutical
formulations in the world by volume.
However, in terms of turnover, the
contribution of the Indian pharma
industry is less than two per cent of the
global total. This is a clear indication that
the prices of medicines in India are the
lowest in the world. The manufacturing
facilities in India are being upgraded to
the standards of the regulated markets.
Today, India has the highest number of
Food and Drug Administration (FDA)-
approved facilities outside the US.
Packaging technologies that show
great potential for growth are horizontal
and vertical form-fill-seal machines for
different goods, be it solids, granules
or liquids. Global packaging giants like
Alcan, Honeywell, Volpack, Sarong and
Theegarten Pactec have partnered with
companies in India to leverage on the
potential of the Indian pharma companies.
How can Indian manufacturers deliver global innovations while maintaining a steady cost-quality ratio?The key to introducing innovation is to
have a strong Research and Development
(R&D) set up. Many good companies
not only have a structured product
development cell, but also invest in R&D.
For example, ACG has its own R&D
center (Scitech Center) exclusively for
delivering innovative solutions. Research
is a low-cost investment as compared to
development cost overseas, and a large
number of Indian designers are now
capable of involving world-class standards
in developing cutting-edge innovations.
What are the main challenges confronting this industry today?Customers today are looking for
convenient, counterfeit-proof and
informative solutions. Convenience
coming from unit dose packs (single-use
cough syrup dose, etc), anti-counterfeit
solutions such as Brandshield printing,
specialised packaging films and track-
&-trace technology are gaining
importance. All these pose a challenge
for companies like ACG, and the R&D
and innovation teams continuously work
towards helping customers overcome
these challenges.
What are some of the R&D initiatives taken by ACG?Anti-counterfeit solutions and methods
of providing patients with safe & genuine
medicine is the current focus. ACG has
established end-to-end anti-counterfeiting
capabilities. Beginning with Brandshield
printing on capsules (in two and four
colours) to unique blister packaging films
(metalised with logo embedded) and, finally,
the supply chain security solution, Verif-i
from ACG Inspection, ACG is all set to
cater to every need of the pharma industry.
How do you perceive the future of the pharma industry in India? India’s pharma industry has approximately
3,000 active pharmaceutical ingredient-
manufacturing facilities, nearly
5,000 formulation facilities and
2,000 other pharmaceutical facilities. Of
these, 300 facilities are in the medium to
large range. Some sub-sectors, including
biotechnology, bioinformatics, contract
research and manufacturing services,
clinical research organisations and pharma
machinery manufacturing, are growing in
tandem with the larger pharma industry,
as experienced human resources and
investments spill over into these areas.
Indian machines are manufactured
and used in accordance with international
standards and are not hazardous to
inspection and approval of their facility.
This is one of the many reasons that India
has the highest number of FDA-approved
facilities in the world. With more and
more multinationals contracting out their
manufacturing to India or setting up their
own facilities in India, the demand for
pharma machinery would only increase in
the coming years.
Email: [email protected]
Aj i t S ingh
An invite that rewards as well...Dear Reader,
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Published by Infomedia 18 Ltd, ‘Modern Packaging & Design’ is one of the leading bi-monthly magazines exclusively for manufacturer and user fraternities of the packaging industry. Well supported by a pan-India readership of over 80,000 and our strong network of 26 branch offices across the subcontinent, this magazine reaches out to key decision makers among the manufacturers of products, machinery and allied segments. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost.
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Business InsightsTechnologies
Opportunities
ANNIVERSARY SPECIAL
Modern Packaging & Design July-August 2012 27
Design CAD/CAM technology ................................................................................................................................ 28 Digital v/s offset printing .............................................................................................................................. 30 Interface: Alpana Parida, President, DY Works ....................................................................................... 33
Shyam Sundar B K, Chief Designer-Industrial Design, Tata Elxsi ........................................ 34 Roundtable: How do packaging designs influence consumer choice vis-à-vis the product? ...................... 35
Materials Food and beverage packaging ...................................................................................................................... 36 Flexible packaging ......................................................................................................................................... 38 Interface: APVS Chakravarthi, Managing Director, Ecobliss India Pvt Ltd ............................................. 42 Roundtable: Can India ride the wave of innovations in bioplastics packaging? ........................................... 43
Machinery Robotic palletiser .......................................................................................................................................... 44 Conveyor technology ..................................................................................................................................... 46 Interface: Avra Mitra, Senior Manager-Key Accounts, Business Unit-Web Fed, Bobst India Pvt Ltd ..............49
Yatindra R Sharma, M D, KHS Machinery Pvt Ltd ............................................................... 50Logistics
Packaging for cold chain .............................................................................................................................. 52 Reverse supply chain .................................................................................................................................... 54 Interface: Frank Oliveri, Vice President-Marketing, Packaging Resources Group, MeadWestvaco ........... 56
Roundtable: How can the packaging industry overcome the logistic challenges posed by Indian infrastructure? ........58Safety
Fresh food packaging ................................................................................................................................... 60 High-speed packaging lines .......................................................................................................................... 62 Interface: Krishnamachari Ravi, Managing Director, Hassia Packaging Pvt Ltd ............................................ 64
Naushik Kabra, Director, Synthetic Packers Pvt Ltd ................................................................ 66Security
Brand protection ........................................................................................................................................... 68 Package testing equipment ............................................................................................................................ 70 Interface: Karl Vandenbussche, Director, Reynders Label Printing India Pvt Ltd .................................. 72
Satyadeep Ray, Director, Holostik India Ltd ............................................................................ 73Sustainability
Packaging material ....................................................................................................................................... 74 Reducing carbon footprint ............................................................................................................................. 76 Interface: Pramthesh Pandya, Head-Unit & Business Development, Parikh Packaging Pvt Ltd .............. 78 Roundtable: Can recycling technology in India achieve competitive results for the market? ...................... 79
Modern Packaging & Design July-August 2012 27
ANNIVERSARY SPECIAL
‘Pack’ing a punch with innovation
DESIGN: CAD/CAM technology
28 Modern Packaging & Design July-August 2012
Packaging is a complex subject and deriving an innovative design is a highly challenging task. Lionel Alva assesses how the advent of novel technologies such as three-dimensional modeling through CAD/CAM has spurred innovation in packaging designs.
Integrated solutions for cost-effective designs
The rate at which a new product
or its packaging variants
reaches the market to achieve
brand consistency across a
variety of substrates as well as the wide &
varied geographical spread of production
units are quite rightly viewed as areas
of additional attention for all major
international brand managers. Energy
management and waste minimisation
are some of the key considerations while
building packaging designs.
Design optimisation is the key to
achieve this, and conventional prototyping
methods have several limitations when
compared to Three-Dimensional (3D)
modeling solutions, which is a more
accessible approach. A Computer
Aided Design (CAD)/Computer Aided
Manufacturing (CAM) 3D modeling
solution would not only give the
designer a great degree of flexibility, but
also enable him to create accurate and
realistic images. With the conventional
approach that is usually a highly time-
consuming and arduous process involving
a keen scrutiny of various elements of
packaging design and in comparison
CAD/CAM solutions are quicker, more
efficient and approachable as a design
medium that completely integrates into
the manufacturing function.
An integrated CAD/CAM solution
offers specialised software and hardware
tools that add to the prowess of
a packaging manufacturer in the
value-added chain of printed packaging
– designers, brand managers, repro
houses, printers and materials suppliers
– to ensure that brand objectives are met
within the best possible timeframe.
When broken down to its base
elements, the CAD and CAM process
is merely a geometric model of the
product being designed. Activities of the
CAD process include mass properties,
finite element analysis, dimensioning,
tolerance, assembly modeling, generating
shaded images as well as documentation
and drafting. Activities of the CAM
process include Computer-Aided Process
Planning (CAPP), Numerical Control
(NC) programming, design of injection
moulds, Coordinate Measuring Machines
(CMM) verifications, inspection, assembly
via robots and packaging.
Widening prospects“We have been working closely with
manufacturers to understand their needs
and have integrated these into the product
solutions that we provide. It is important
to understand the finer nuances of the
manufacturing process before the product
solution is made available to manufacturers
so as to ensure complete integration while
ensuring that the interface for our solution
remains accessible, and we try & reduce
28 Modern Packaging & Design July-August 2012
Cou
rtes
y: A
very
Den
niso
n
DESIGN: CAD/CAM technology
CAD/CAM technology
Modern Packaging & Design July-August 2012 29
the learning curve to the maximum extent
possible. Some of the key considerations
for our solutions are that these should
seamlessly work with the environment and
automatically accommodate changes to
design models while facilitating a smoother
flow of the heterogeneous packaging
process,” avers Sambit Pradhan, Business
Development Manager, and Product Sales
Asia Pacific, Geometric.
In the Indian context, packaging
manufacturers are increasingly exploring
avenues that offer a suitable alternative
to the time-consuming and expensive
conventional prototyping methods.
Considering the varied nature of
packaging designs, the use of 3D
modeling techniques appears to be
the most pragmatic approach towards
manufacturing. Indian CAD/CAM
manufacturers ensure that the CAD/
CAM solutions they offer cater to the
business dynamics of emerging economies
while remaining accessible and cost-
effective. Since a CAD/CAM technology
is a mix of hardware and software, the
technology strives to achieve optimum
and focussed product development
characteristics.
Recent developments in CAD/CAM
solutions show that the best solutions
help manufacturers increase productivity
and profitability through best-in-class
technologies and adaptable automation
tools that maximise machining efficiencies.
While being simple to use and eliminating
the drudgery of CNC programming with
intelligent machining through automation,
the best advantage is perhaps that packages
can be constructed from scratch within a
few seconds. The constructions lead to
data that can directly be used by other
departments in a company similar to any
production engineering unit (cutting,
grooving, drafting, scoring, milling, laser,
etc). The software simulates folding steps
that enables the feasibility monitoring of
one’s new construction during the packaging
design process. The automatic 3D display
as wireframe graphics with hidden lines
allows simulation and recall of folding
steps for an easy, rapid and efficient
packaging design.
Some of the major advantages are:
Visualise an idea quickly and
efficiently
Modify modeled ideas to record
and evaluate the consequences of
their action
Model concepts, such as nutritional
analysis
Represent ideas using real-time
simulations, eg, virtual reality
Use an outline specification proforma
to aid product design
Monitor and control production to
ensure food safety and a consistent
outcome, eg, hazard
Hazard Analysis and Critical Control
Points (HACCP)
Ensure accuracy, especially precise
weights and measurements
Challenges with softwareCAD and CAM are relatively new areas of
technology that have come to fore in recent
years. Understanding and implementing
CAD and CAM can represent a
challenge, especially since a keen scrutiny
of the packaging manufacturing process
is needed. Moreover, the hardware and
software must fit the requirements or the
integration could be a complete failure,
further exacerbating the problems of
the manufacturing process. There is also
a steep learning curve associated with
CAD/CAM software, and requires highly
skilled and dedicated personnel. When
two or more software packages need
to communicate, there is always room
for error. Sometimes it may be a minor
problem, but often the problem becomes
severe. Each software supplier writes its
own code to handle complex geometry.
In case of any differences in the way, one
or the other describes a lofted surface, for
example, one will not get exactly the same
shape as was intended. However, with an
integrated product, with both CAD and
CAM, this possibility can be reduced to a
great degree. Significant strides have been
made in the training and implementation
to help accelerate the processes. Once users
pick up pace, they become self-sustaining
and establish the best practices required to
operate and maintain the system.
With the range of machine tools,
cutting tools and automated machines
required, the initial setup cost
could become expensive for Indian
manufacturers. Moreover, there is a
possibility that the CAD/CAM solution
may not be compatible with new
manufacturing processes introduced,
thus requiring a complete overhaul
of design.
Future of CAD/CAM technologyConsidering that the packaging industry
is constantly evolving and finding
new areas of application, CAD/CAM
technology could go a long way in
furthering the prospects of a packaging
manufacturer. It is an excellent fit for
high volume production where the focus
is on shorter lead times, especially in the
Indian context, since the retail boom and
the demanding nature of the clientele in
India requires an absolute optimisation of
the manufacturing process.
Email: [email protected]
Sambit PradhanBusiness Development Manager, and ����!����������������������������
It is important to understand ��������������� ������manufacturing process before the product solution is made available to manufacturers so as to ensure complete integration while ensuring that the interface for our solution remains accessible, and we try & reduce the learning curve.
DESIGN: Dig i ta l and of fset pr int ing
To a large extent, the packaging
industry, especially for the
retail sector, is driven by the
impulses of the consumer,
and which is why the appealing nature
of a design can make or break the
success of a given product in a market.
Such is the crucial nature of design,
and thus it is extremely important that
the technical aspects of the design
philosophy have a sound basis. While
often overlooked, the approach towards
the nature of printing used can have
an inordinate effect on the successful
fruition of a strong design philosophy.
When a consumer enters a retail store,
he faces a kaleidoscope of colours and
textures where a product that stands
out on the shelf will arrest his attention
immediately. This effectively underlines
the powerful impact of colour in
packaging design and the psyche of the
customer.
The question that most package and
label converters in India ask themselves
is whether they should opt for digital
or offset printing. It is important
to understand the strengths of
each technique and the quality
considerations of the design since
choosing the wrong method could
be detrimental to the organisation’s
image and stand to compromise brand
integrity and affect its equity in the
market. In the end, a good design cannot
fully live up to its potential if run on a
poor print job. If a manufacturer is as
careful and selective in choosing a print
partner as he would be in choosing a
design firm, one can ensure that the
final product reaches the highest quality
parameters.
Economics of printingWhile assessing different print
technologies an understanding of the
terms ‘Cross-over’ or ‘breakpoints’ is
important. This is when the comparable
cost of a production run between, say,
digital and offset, becomes the same.
Moreover, as technological paradigms
are constantly changing, so are the
cost-value facets of digital and offset
printing. Digital printing has all the
advantages on the front-end, as setup is
essentially free, but the price per label
slowly rises with production. However,
it is still too slow for large runs. Offset
starts out as expensive with non-flexible
and laborious setup, but as numbers
increase, the unit cost per label declines.
Flexo and offset presses run considerably
faster than digital presses. Printers talk
in terms of feet of paper per minute.
30 Modern Packaging & Design July-August 2012
Weighing the pros and consThe retail market is driven by consumer-
centric designs with varied visual appeal.
Among the various design considerations,
it is the method of printing used that is
important. Lionel Alva explores how digital
and offset printing consolidates the
disintegrated packaging industry with an
approach to create appealing label designs.
DESIGN: Dig i ta l v/s of fset pr int ing
Courtesy: Avery Dennison
32 Modern Packaging & Design July-August 201232 Modern Packaging & Design July-August 2012
Digi ta l v/s of fset pr int ing
For instance, digital production on a
Hewlett-Packard WS-4500 at best is 50
ft/min. Offset can print hundreds of
feet of substrate per minute. There is
a point of ‘equal’ exchange or ‘cross-
over’ where, briefly, the costs equate.
For the WS-4500, this translates into
about a 5,000-case labeling run, which
is a substantial figure. Thereafter,
offset starts to be cheaper.
“Currently, digital
printing renders
colours more
a c c u r a t e l y
and on a
comparative basis, creates more vibrant
and appealing designs. Digital printing
is also far more flexible for design
changes that may happen. However, it
is better used for smaller volumes and
offset printing for larger volumes, since
otherwise the economics just do not
play out, especially in the Indian context
as the market is quite cost-sensitive.
The dimensions of the packaged
product and several other factors are
important, bearing weightage on the
nature of printing used. Moreover,
digital printing technology constantly
evolves requiring re-training of employees.
Hence, currently, it is not feasible but is
gaining increased interest due to more
innovative design protocols and their
immense potential,” avers Shrikant Naik,
Director, Alpha Prints & Labels.
Different considerations will
determine which method is the best,
such as quantity, timing and size of
the printed piece. Offset printing is
commonly used for higher quantity,
larger-format jobs, while digital printing
is best applied to smaller-format, lesser
quantity print runs.
Understanding the methodsOffset printing, however, works as a
more conventional publishing process
from where the inked graphic from the
completely ready plate is transferred
to the rubberised blanket later, and
lastly into a publishing spot such as
cardboard or document. Offset printing
is mostly employed in conjunction
with lithography, which works to the
reverse components with oil and liquid.
The graphics to be published will get
an oil-based toner through the offset
machine’s wheels. A non-printing
spot, nevertheless, extracts a
small layer of liquid, which
often prevents printer
ink from flooding
a non-printing
spot.
Handling the cost of digital printers
is higher than that of offset printers, and
thus gets a big portion of the business’s
operating spending plan. Offset printers,
however, generate high-quality replicates
by applying low-cost and swift plates.
“When done correctly, offset printing
creates appealing designs, is more cost-
competitive and poses lesser maintenance
hassles since its intricacies are well
understood by manufacturers. Digital
printing is still a new form of technology
and requires some time before it gains
acceptance in the Indian scenario, which
is the case with any new technology,”
asserts Naik.
Merits and demeritsEven though offset printers take
advantage of basic oil-based toners,
electronic equipment depend on costlier
specific inks and toners. Furthermore,
despite the fact that offset machines
could print on all types of papers and
other materials, eg, vinyl, lumber, textile
and steel, digital printers require unique
paper stocks, which are specifically made
for digital printing. Obviously, these
stocks cost more as compared to the
standard types. Since digital printing
is a new form of technology, it has
brought about several advancements,
more options and several features that
have increased the printers’ interests.
However, currently its application is
limited since Offset printing is still a
more cost viable technique for large
volume production. Printers must,
therefore, carefully scrutinise their
project demands and digital printing can
provide them with an added flexibility.
Ultimately, everything is depends on
the project demands, ie, whether a client
should choose digital or offset printing.
And, unless an even better approach to
produce high-volume duplicates at low
costs and effectively is created, offset
printing is here to stay.
Email: [email protected]
Shrikant NaikDirector, Alpha Prints & Labels
Digital printing technology constantly evolves requiring re-training of employees. Hence, currently, it is not feasible but is gaining increased interest due to more innovative design protocols and their immense potential.
DESIGN: Inter face - A lpana Par ida
Modern Packaging & Design July-August 2012 33
“Innovations in packaging design can drive market growth”
How has packaging evolved into a branding tool today?This trend emerged when more advertising
meant higher awareness, which meant
more marketshare. Today, with incredible
media clutter, brands need to make
huge expenditure to garner awareness.
Advertising, in a bid to differentiate them
and be memorable, tells stories that are
memorable but does little for the brand.
Also, as categories, brands, variants
and stock-keeping units proliferate, the
consumer expects choices at the retail
shelf. Here, packaging plays a huge role
in causing conversions at the retail shelf
and thus can expand marketshares.
What are the key design elements essential to successful packaging?The structure of packaging has to break
the clutter and take the brand value
forward. Further, the substrate and
printing can indicate the brand’s values.
For instance, the metallic substrate of
Taj tea positions it as premium, and the
special red colour used by Colgate ensures
that there is no imitation.
Subsequently, the front of pack design
must follow the messaging hierarchy for
the brand. What does the consumer need
to know first? What role does the image
play? Finally, the back of pack design must
convert the consumer. All information
should be included at the back of the
pack – Is it easy to use? What is the usage
guideline or ingredients?
What are the current market trends in packaging design?Packaging must play a role in attracting
attention, creating awareness, educating
consumers and converting them to make
a sale. Innovations in packaging design
can drive market growth and brand
penetration. These innovations can be of
low cost but must be able to break the
clutter in this highly populated multi-
brand retail environment. Some marketers
are experimenting with substrates. For
instance, the new Lakme skincare range
created by us has various substrates, from
regular to premium products. The use of
metals is seen in categories such as food,
personal care and household products.
In India, this clearly signifies a premium
experience. Also, if value addition to a
product is significant, consumers will
pay for it. Innovations in packaging can
command a premium and higher margins.
Which technologies are required to implement new packaging designs?Often, it is not technology, but an
innovative mindset, both on part of the
design agency and the client, that matters.
For example, a bag of flour/rice with a
zip lock, a stand-pouch with a gusseted
bottom for sugar, a vertical pack for cereals,
etc, none of these requires new technology.
How do you assess the Indian packaging industry vis-à-vis global developments?In India, the issue is not capability, but
the tendency of Indian business to shun
innovations. We still opt for the lowest
cost, common structures. Only few brands
invest in new structures or designs, eg,
cigarettes that experiment with printing,
substrates and textures.
Email: [email protected]
…says Alpana Parida, President, DY Works. With an experience spanning over two decades in retail and marketing communications, Parida believes branding to be the new advertising. She emphasises that today’s packaging solutions must add value through innovative & functional designs, in an exclusive interaction with Annabel Dsouza.
Photo: Joshua Navalkar
DESIGN: Inter face - A lpana Par ida
DESIGN: Inter face - Shyam Sundar B K
34 Modern Packaging & Design July-August 2012
“Creativity must be pushed beyond the comfort zone to achieve maximum expectations”
What approach do you take towards creating innovative packaging solutions? While developing a new pack, a designer
can look towards numerous aspects of
innovation. It could be a technological
innovation that a brand needs to
communicate or usability of the pack,
which enhances consumer experience
or a pack that challenges the trend
in the category. Innovation could be
driven by the design objective defined.
If sustainability is the key objective,
then the ideas that occur would
be based on packs that reduce
the amount of material used, its
amenability for recycling/reuse,
alternative cost-effective solutions,
etc. Similarly, the aim could be
user convenience, material change,
cost reduction, etc. Inspirations and
developments f rom other industries
also facilitate new thoughts that can be
induced to bring in innovation in the
development of packaging solutions.
What is the scope and relevance of digital printing in the Indian market today?To be specific, digital printing has
become an imperative for Fast-Moving
Consumer Goods (FMCG) companies.
Because of high quality of printing,
more brands are now looking at this
as an option. Innovative methods can
help designers to quickly print, evaluate
designs and develop artworks, thus
helping to reduce the development time.
Increase in private label with short runs,
customising to target markets, etc are
also some of the reasons that have given
a boost to digital printing.
How much emphasis does Tata Elxsi place upon environmental sustainability for packaging solutions?The solutions developed at the
company are highly influenced by the
client, and this gets articulated in the
project objective. However, the concepts
developed by us are evaluated on
various parameters, and sustainability is
an important aspect that is considered
during the process. We have also carried
out specific sustainability projects
related to packaging.
What challenges are faced while designing a creative, yet sustainable and cost-effective packaging solution?Packaging should satisfy several
expectations. In the process, it is a
balance of various attributes versus
sustainability that must be evaluated
in order to take conscious decisions.
Creativity must be pushed beyond the
comfort zone to achieve maximum
expectations without compromising on
sustainability.
How do you see the future of the packaging industry and what are the major drivers shaping packaging trends today?Innovations in technology are currently
ruling this industry. Also, the influence
of other industries is now fairly seen in
packaging, such as the use of dual colour/
feel on packs; gadgets that help dispense
the product; incorporation of electronic
intelligence into packs, etc. The future
of packaging will be defined by the cost
to manufacture and cost to environment,
as consumers become enriched as well
as responsible. Packs that are easy to
use and dispose as well as suitable
for recycling will be more acceptable
in the future.
What is your approach towards understanding consumer requirements while creating a fully integrated packaging solution? As rightly said, we have 4-5 different broad
clusters of geography that probably have
certain common taste and preferences. It
is important to know that people trust the
brand and value the product. Packaging
becomes a functional and emotional carrier
towards achieving this objective. Hence,
an ethnographic study to understand the
consumer needs can help gather insights
in order to develop a successful product
and its packaging. Although simpler in
appearance, packaging becomes complex
with diverse customer preferences, and
there are numerous challenges every time
to meet their expectations.
Email: [email protected]
…asserts Shyam Sundar B K, Chief Designer-Industrial Design, Tata Elxsi. In an interaction with Lionel Alva, he describes his approach towards creative solutions while touching upon several key facets of the packaging industry and the trends driving it forward.
DESIGN: Roundtable
Modern Packaging & Design July-August 2012 35
Makdum Jahan Country Manager,
Veripack Solutions India Pvt Ltd
The Indian packaging sector is perhaps the most dynamic one and driven by innovation. Only the most imaginative packaging designers can survive in a highly competitive and demanding environment. Those in the retail sector compete to build appealing, informative and cost-effective designs, which will ultimately affect the psychology of the customer, and thus influence his purchasing decision. Achieving and fulfilling design expectations is a difficult and challenging proposition. Therefore, it is vital to have courage to adopt various trends and factors driving the market today. We must address several facets such as graphic design, dimensions and nature of packaging as well as packaging quality considerations, which makes the science of packaging extremely challenging yet rewarding. The rapid rise of the retail sector in India has changed in its approach towards packaging, and even established brands now have to constantly strive to sustain bottomlines.
The surge in supermarkets and retail stores has driven the need to better understand the consumer decision making process. Lionel Alva assesses how deeply packaging design affects the consumer’s decision making vis-a-vis other aspects such as quality and brand image.
M K Banerjee Director-Creativity & Innovations,
Essel Propack
Innovative package design reflects the quality of the product packed inside. Often, the packaged product cannot be seen from outside, but from the graphics and packaging information, one can easily correlate the sentiment & seriousness of product manufacturer to ensure that the product quality remains intact throughout its designated shelf-life. Smart and innovative packaging design includes intrinsic properties of the packaging material as well as the look, feel and functionality of a complete package. Consumer convenience is also a great enabling factor as the packaged product should be easy to dispense, consume and retain for future use. Controlled-Atmosphere Packaging (CAP) and Modified Atmosphere Packaging (MAP) designs preserve the filled product to its original freshness and texture. Today’s consumer wants to know from the packaging if the product is genuine. Hence, the brand and packaging designer must incorporate anti-counterfeit measures into the basic packaging design.
Manisha Joshi Director, Isha Enterprises
The packaging industry today is driven by creativity and innovation. This is in terms of design as well as nature of materials used for packaging where companies constantly strive to push the boundaries of possibilities. However, designers can merely take the brief from clients and give them different ideas based on their criteria. Then they conduct a market study to analyse the feasibility of the packaging design, dimensional considerations and overall costs. Understanding the psyche of the consumer can, at times, be a perplexing and tricky challenge. This is because taste is a subjective notion, and there is no such thing as a bad design, but figuring out what works and what does not is a challenging task. In the past, often, a design rejected by one organisation has been taken up by other organisations who have successfully integrated it into their product. Understanding the varied nature of consumer taste in India is undoubtedly the most challenging proposition.
The dominance of the retail market has put a singular emphasis on understanding consumer wants and needs better. As companies strive towards innovation, the quality of products is also increasing with packaged products witnessing an improved shelf-life.
Editorial take:
How do packaging designs influence consumer
choice vis-à-vis the product?
Email: [email protected]
MATERIALS: Food & beverage packaging
Carving a niche in the Indian market
Indian packaging industry is
thriving, and of late, it has been
the focal point of tremendous
opportunities for manufacturers.
Its exponential growth record in India
varied by 22-25 per cent annually
as compared to the global rate of
4-5 per cent. The dynamics of the
industry are slightly fragmented and
unstructured, but with terms such as
global villages turning into reality,
industry players are adapting to modern
and advanced technology providing
world-class products. Currently, the
packaging industry is in a transition
period due to increasing awareness
among customers. Quality, hygiene and
face value are making imprints in the
minds of people.
Packaging offers better shelf-life for
products and helps retain the flavour
for prolonged periods. This assists
the consumers in their normal busy
life. India being the world’s second
largest and third largest producer of
vegetables and fruits, respectively, is
focussed more on packaging to meet
stringent international standards. The
growth parameter for the packaging
industry is directly linked to the growth
trends of the Fast-Moving Consumer
Goods (FMCG) segments, which is
highly influenced by consumer choice.
High disposable income has enhanced
the lifestyle of consumers who,
today, have wider choices available in
the market.
Latest innovations An increasing population and growing
consumer demand for packaged foods
has forced the Food & Beverages (F&B)
industry to look at new technologies
that provide flexibility, ease of
operation and constant tracking of the
production process. Suresh Singhal,
Managing Director, Himalayan Group
of Industries, says, “Manufacturers are
working on guidelines for maintaining
transparency in the production process
for assuring consumers’ health and
hygiene. This demands continuous
monitoring and efficient traceability
of the entire production process in the
food processing plant. Innovation is an
ongoing process, and we cannot rule
out any possibility in developing new
materials for new packaging.” Numerous
trials are being conducted to make new
materials suitable for better packaging
and also make these more economical
& environment-friendly
Working on innovative ideas for
cost-effective solutions, environment-
36 Modern Packaging & Design July-August 2012
MATERIALS: Food and beverage packaging
Food processing and packaging technologies have undergone significant changes over the last decade, in terms of new methods of processing foods, packaging materials and techniques of manufacturing containers. Anwesh Koley delves deeper into the changes that have occurred in the area of plastics and other materials and the future of food & beverage packaging.
Cou
rtes
y: H
imal
ayan
Gro
up o
f Ind
ustr
ies
Food and beverage packaging
Modern Packaging & Design July-August 2012 37
Suresh SinghalManaging Director, Himalayan Group of Industries
Availability of good-quality raw material, fully automated machines and hygienic manufacturing process are making plastic packaging a more suitable option for F&B industry. These factors are helping to change the psychology of the Indian consumers to wipe out apprehensions about canned food products.
Modern Packaging & Design July-August 2012 37
f riendly alternatives and appealing
appearance vis-à-vis competing with
international standards is the target of
Indian convertors. Disposable packaging
materials used to ship and protect
purchased items as well as disposable
containers used for F&B packaging are
of particular interest today. New product
avenues using the thermoforming process
for fruits, vegetables and ice-cream will
change the perception of packed food
criteria. Packaging companies across the
country are tracking these innovations
and aggressively moving towards adding
value to the packaging industry.
Rigid packaging technology Glass packaging had a global monopoly
over F&B packaging for a very
long time. Recent advancements in
plastic materials such as Polyethylene
Terephthalate (PET), Polypropylene
(PP), Polycarbonate (PC), High-
Density Polyethylene (HDPE) and
Low-Density Polyethylene (LDPE)
are presenting strong competition to
the traditional concepts of packaging.
Universal standards and compliances for
establishing non-toxic plastic products,
has not only brought down the overall
cost of packaging, but also made it
viable for safe transportation. Another
advantage that keeps rigid packaging
ahead is its tamper-proof characteristics.
Consumers still do not trust packaged
food items manufactured in India, which
is in complete contrast with globally
manufactured and packaged food. But
with steadily increasing awareness, the
demand is slowly increasing. Emphasis
on zero-toxic, Bisphenol A (BPA)-
free products is ensuring healthy and
hygienic products. “Availability of good-
quality raw material, fully automated
machines and hygienic manufacturing
process are making plastics packaging a
more suitable option for F&B industry.
These factors are helping to change the
psychology of the Indian consumers to
wipe out apprehensions about canned
food products. Today, it can be said
that the Indian packaging industry
adheres to international standards, as
many of them are Original Equipment
Manufacturer (OEM) suppliers to
world-class companies,” adds Singhal.
Hygiene standards Much attention is being given to
preserving health, safety and hygiene
of the product. A major challenge for
the packaging industry is to retain the
essence of the packaged food products.
As these products are carving a niche in
the Indian market, innovative ideas are
being implemented to keep the flavour
intact. Production companies are taking
numerous steps to produce the goods
in controlled environment, which results
in reducing contamination. Provision of
clean rooms is an evident example of the
importance given to hygiene.
Tetra packs, PP jars and containers,
and many others have replaced the
kitchen shelf, as they are much easier to
maintain and have better shelf-life. “Till
date, the emphasis of hygiene was laid
only on the pharma sector, but today,
we notice similar compliance for F&B
packaging as well,” mentions Singhal.
Tackling the competition Plastics packaging is facing tough
competition from conventional style
of packaging such as glass and metals.
Singhal laments, “The stigma attached to
plastics due to its chemical composition
and supposedly toxic ingredients is
taking time to change. However, when
it comes to plastics packaging, the pros
outweigh the cons and the consumer is
realising its benefits.”
Other packaging manufacturers
are vehemently pressurising the
Government to ban plastic products
for environmental reasons and trying
to malign the plastics packaging
industry, but with modern technologies
and stringent regulation, care is being
taken to provide environment–friendly,
recycled raw material and low carbon
emissions from the manufacturing units.
Plastics packaging is now accepted
globally in every sector, particularly in
F&B packaging.
Email: [email protected]
Courtesy: H
imalayan G
roup of
Industries
MATERIALS: F lex ib le packaging
38 Modern Packaging & Design July-August 2012
Courtesy: Hi Tech Polyfl ex Pvt Ltd
The consumption patterns in India are changing substantially with demand for better quality and greater convenience increasing. Anwesh Koley gauges the consumption of rigid and flexible packaging and its fast acceptance among consumers.
Flexible packaging finds varied
usage owing to its ability to
provide strength, moisture
resistance, aroma retention,
gloss, grease resistance, heat retention,
sealability, printability and low-odour
properties. Flexible packaging has
gained vast acceptability because of the
protection it offers to the product against
environmental threats such as moisture,
heat and chemical reactions. Convenience
in handling the product and the cost
benefits it provides are some of the added
advantages.
Nonetheless, plastics, which is the
most commonly used substrate in flexible
packaging, faces unfavourable situations
because of environmental protection and
disposal concerns. These issues act as a
major impediment for flexible packaging
that will become an all-pervasive
medium. Moreover, flexible packaging
mandates additional capital requirements
and technical know-how for efficient
manufacturing operations.
Current market conditionGrowing at a compounded annual growth
rate of 17 per cent, the Indian flexible
packaging market is one of the most
dynamic and fastest growing sectors in
the country. Sandeep Jain, Director,
Hi Tech Polyflex Pvt Ltd, says, “As
advantages of flexible packaging such as
ease of handling and lesser storage space
are increasingly appreciated, conventional
rigid packaging will take a backseat. Also,
flexible packaging scores over conventional
packaging for reasons such as keeping
the product away from adulteration and
moisture, convenience of disposal and cost
savings on transportation.”
For a company to be successful in the
Indian flexible packaging market, it needs
to understand the end-user requirements
and provide packaging materials that
offer better barrier properties. Flexible
packaging offers the advantage of
packing smaller quantities as compared
to conventional packaging, and hence
middle-class consumers, who comprise a
major section of the Indian society, have
the choice of purchasing just the required
amount of products.
The flexible packaging market has
received a leg up from growth in the
processed food, personal care and hygiene
industries as well as the the retail sector.
“The demand for smaller packaging and
increasing consumerism due to higher
purchasing power also bodes well for
the market. However, there is a lack of
quality consciousness among end users,
who tend to gravitate towards low-grade
products, thus hampering the sales of
quality flexible packaging. Processors can
dig deep into this fragmented market by
making consumers more aware of the
advantages of flexible packaging, offering
38 Modern Packaging & Design July-August 2012
Responding flexibly to customer demands
MATERIALS: F lex ib le packaging
Flex ib le packaging
superior-quality product lines and pricing
their products more attractively,” adds
Jain. Additionally, the existence of more
than 800 processors in the Indian market
creates a fiercely competitive marketplace,
fostering price wars.
The use of new polymers, which
enhance the packaging requirements as
well as facilitate innovative techniques for
faster packaging, will help companies grow
in the Indian flexible packaging market.
With the advent of metalised films and
other novel materials, the industry is
looking at increasing the quality of the
products, and thereby per unit sales. In
fact, the market is expected to treble
its output in the next seven years from
1,000 kilotonne in 2007 to 3,100 kilotonne
by 2014 owing to the greater demand
from the processed food, pan masala and
other retail products.
Benefits of paper packagingAlthough substrates such as plastics have
gained vast acceptability, attractiveness of
paper and paperboard consumption remains
high. Currently, India is ranked 15th in
the world for its paper and paperboard
consumption and is expected to improve
its rank in the future. Paper is the fastest
growing substrate segment with a growth
rate of 6-7 per cent. The total demand for
paper is currently estimated to be about 6
million tonne, of which about 40 per cent
is consumed by the packaging industry. If
the demand for paper continues to grow at
the same rate, total paper consumption is
expected to double by 2014.
India vis-à-vis global marketLaminated products including form-fill-
seal pouches, laminated tubes and tetra
packs are growing at about 30 per cent
per annum. There are about 600-700
packaging machinery manufacturers,
95 per cent of which are in the small
and medium sector located all over
India. Germany and Italy are the latest
suppliers of packaging machinery to
India, but the focus is now shifting
on Taiwan, Korea and China. Indian
packaging machinery imports are at
$ 125 million.
The Indian packaging machinery
exports are rapidly growing and India
has emerged as a key importer. India’s
per capita packaging consumption is less
than $ 15 against the worldwide average
of nearly $ 100. “The large growing
middle class, liberalisation and organised
retail sector are the catalysts for growth
in packaging, while the food & pharma
packaging sectors are the key drivers,”
adds Jain.
Corrugated box packaging marketMultinationals are demanding corrugated
boxes of international standards and the
buying pattern is changing rapidly. Prices
of corrugated sheet and converted boxes
have remained low due to over-capacity,
manual operations and low productivity.
Besides, transport constraints and high
freight costs have meant that small- to
medium-sized corrugated box plants are
located near the customers.
Modern Packaging & Design July-August 2012 39
40 Modern Packaging & Design July-August 2012
Flex ib le packaging
Sandeep Jain/��������������������[��]��}��
There is a lack of quality consciousness among end users, thus hampering the ����� ����������������packaging. Processors can dig deep into this fragmented market by making consumers more aware of the advantages ������������������� ��������superior-quality product lines and pricing their products more attractively.
Currently, India has over 4,000
corrugated board and sheet plants, which
are highly labour-intensive and employ
over half a million people – directly and
indirectly. The industry is converting about
two million tonne of Kraft paper into
corrugated boxes. Factories are spread out
in all parts of India, even in the remote
industrially backward areas. “This present
scenario is already being challenged by the
sweeping changes that are beginning to take
shape. More and more in-line automatic
plants are being set up, as corrugated box
makers gear up to meet the new demands
for high-precision boxes with attractive
graphics and large integrated production
capacities,” adds Jain.
In-line, automatic board and box
making plants will ease out the present
semi-automatic production processes.
Deployment of folder gluers, rotary
die-cutters will be on the rise, besides
the use of corrugated sheets for display/
promotional packs, package-on-package
solutions and dispensers. Advancements in
multi-colour, flexo printing will facilitate
in-house flexo printing and eliminate the
use of screen printing, contract printing
on offset presses.
The way forwardThe growing Indian middle class, along
with the surge in organised retail in the
country, is driving demand in the flexible
packaging industry. Another factor that
has provided a substantial stimulus to the
packaging industry is the rapid growth
of exports, which requires superior
packaging standards for the international
market. Moreover, in terms of the ease
of use, flexible packaging offers greater
flexibility to the consumer, and this has
been accepted in the market. “A package
must protect what it sells and sell what it
protects. Modern methods of consumer
marketing would fail were it not for the
message communicated on the package.
The information provided on packaging
allows the consumer to make informed
decisions on the product’s purchase and
use,” concludes Jain.
Email: [email protected]
42 Modern Packaging & Design July-August 2012
MATERIAL: Inter face - APVS Chakravar thi
“Innovation is the key for success in the packaging industry”
How is the pharma packaging industry shaping up in India?There is no distinction between the
packaging industries about whether they
belong to pharma packaging exclusively or
otherwise. But, many packaging companies
maintain their exclusivity, contributing
towards the pharmaceutical sector. This
can be individual or a combination of
two or more segments such as blister
packs, vials, tubes, caps and closures,
flow-fill seals, bottles for suspensions,
tubes, blow moulded containers,
thermoforming blisters and bulk drug
containers, besides the regular printed
boxes, labels, flexible laminates, etc.
Many of the above segments cater
to non-pharma industries such as Fast
Moving Consumer Goods (FMCG) and
electrical/electronics, but the packaging
industries supplying to the pharma
sector maintain their uniqueness because
of the high standards essential to this
application. Pharma packaging industry
in India is growing by about 15 per cent
as against 5-6 per cent annual growth
rate in western countries. Although we
still lag behind in producing the basic
packaging materials for pharmaceuticals,
the converting and machinery industry is
poised to reach global standards.
What innovations has this segment witnessed over the years?While tremendous improvements have
been made in developing new drugs
and molecules, the packaging industry
in India is still to match the pace of
innovations happening in product
development. Nevertheless, many
significant initiatives have happened of
late in packaging.
The use of heavy drums that
contribute to massive transport
costs when shipped empty to the
manufacturing company is minimised
abroad. Polypropylene collapsible bags,
with corrugated board lining have
been extensively used outside India for
carrying bulk drugs or intermediates.
This trend is slowly being adopted
in India as well. Similarly, packaging
supplied to formulation industries has
seen a dramatic development in the
recent past to keep pace with global
requirements. Smart packaging using
Radio-Frequency Identification (RFID)
technologies is set to grow in future with
demand from the user industry.
India has undergone a radical change
in the last decade, with a dramatic
improvement in consumer awareness. This
paved a new era in primary packaging
industry for pharmaceuticals to produce
better patient-interactive packaging.
What R&D initiatives have you undertaken over the years?We understand that packaging is essential
in capturing that ‘first moment of truth’.
It takes only seconds for a consumer
to notice a product on the store shelf.
And that moment presents an incredible
marketing and selling opportunity. Nearly
70 per cent of all purchase decisions are
made at the shelf. Almost half of all
packaged goods are sold without any
additional marketing support. Considering
the way conventional medical shops have
transformed into organised pharmacies,
the above statement holds true for pharma
packaging.
Providing innovations and appropriate
solutions is the key to success in the
demanding and ever-changing market of
blister and high-visibility packaging. We
must stay updated on key developments in
blister and high-visibility packaging and
share this knowledge with our customers
in order to achieve breakthrough
packaging solutions. Keeping in view
the demand from the industry, Ecobliss
has taken steps in developing senior-
friendly, child-resistant, tamper-evident
and patient-interactive packs. All
products made by us are compliant
with global standards.
What are the challenges you face in India?Cost has always been a major
challenge for Indian pharma packaging
manufacturers. While standards must
not be compromised below global levels,
pharma industries in general are not
really prepared to spend at the same
level in India. Hence, it is always a
usual challenge to balance both factors.
Moreover, like in the industry (pharma)
it caters to, packaging also is witnessing
imitations and counterfeiting. However,
final decision making rests with the
industry and its consumers.
Email: [email protected]
…believes APVS Chakravarthi, Managing Director, Ecobliss India Pvt Ltd. In an interaction with Anwesh Koley, he explains various trends in the high-visibility packaging segment and the challenges faced by the industry in India.
MATERIALS: Roundtable
Modern Packaging & Design July-August 2012 43
Bharat Rastogi Director, Mono Plastic Industries Pvt Ltd
Indian packaging companies no longer lag behind international players in bioplastics packaging. Bioplastic materials are defined as materials that are biodegradable, compostable and derived from both renewable & non-renewable sources. Since 2010, bioplastics technology is changing, with commercialisation of bioplastics produced directly from natural or genetically modified organisms and introduction of non-biodegradable, bio-derived Polyethylene (PE). These materials are expected to account for a quarter of total bioplastics packaging market demand by 2020 across the world. Polyhydroxyalkanoates (PHA) are forecast to achieve a compounded annual growth rate of 41 per cent and bio-derived PE a staggering 83 per cent over the period.The marketshare of conventional bioplastics packaging technologies based on starch, cellulose and polyester are expected to decline by 2020. Further, flexible packaging is expected to capture a growing share of the bioplastics packaging market in India over the next 5-10 years.
Bioplastic packaging is fast gaining ground globally with manufacturers as well as consumers realising extensive environmental and application advantages. Anwesh Koley gauges the views of some industry experts on the current state of bioplastic packaging in India as compared to the international scenario.
Ravi Kumar Director, Shiv Pooja Plastics
The use of biodegradable materials in the flexible packaging industry is fast gaining interest. Although their use in the industry is still limited, the need to move in the direction of more eco-friendly packaging is acknowledged by both the consumers and the industry and new developments are moving ahead. Producers of films, inks, adhesives and resins are actively involved in research on new materials from renewable sources that are compostable, and whose disposal can limit their environmental impact.
The physical properties of raw materials derived from various vegetable resources are different from those of conventional films. This has a bearing on their machinability, which is of primary importance to a converter’s operations. This has prompted global players in the packaging domain to test and show the capability of their printing and laminating machines to print and convert profitably such new materials, while also continue to improve the efficiency of the equipment in terms of more efficient and sustainable operations.
Neeraj Garg Proprietor, Suruchi Industries
Various bio-based materials and their innovative applications in food-related packaging have gained attention over the past several years. These new materials include starch, cellulose and those derived from processes involving microbial fermentation. Bioplastics development efforts have focussed predominantly upon starch, which is a renewable and widely available raw material. As a packaging material, however, starch-based bioplastics is extremely brittle. Starch alone cannot form films with satisfactory mechanical properties, eg, high percentage elongation, tensile and flexural strength, etc, unless it is plasticised, blended with other materials or chemically modified. Common plasticisers include glycerol and other low-molecular weight poly-hydroxy-compounds, polyethers & urea.
Starch-based thermoplastic materials have been commercialised over the last several years and currently dominate the market of bio-based, compostable materials. Food-related applications include films for food wrapping and thermoplastics for food packaging and other food containers such as plates, cups & egg trays.
The Indian bioplastics industry is witnessing heightened activity due to its numerous benefits. While manufacturers might find it more expensive to opt for biodegradable packaging, what cannot be ignored is that the future of packaging will see increased bioplastics usage.
Editorial take:
Can India ride the wave of innovations in bioplastic
packaging?
Email: [email protected]
MACHINERY: Robot ic pal let iser
44 Modern Packaging & Design July-August 2012
In this age of extreme competition, the demand for reducing overall costs and enhancing the quality of products, has increased the need for automation in manufacturing process. In this backdrop, Avani Jain highlights the advantages of robotic palletisers for precision and safety in packaging operations.
Reducing downtime, enhancing precision
Automation and usage of
robotics in packaging is a
growing trend, as it ensures
better productivity and
efficiency through a combination of
speed & accuracy. Over the past few years,
packaging technology has undergone
a remarkable change, due to the rising
awareness of the Indian consumer. The
modern Indian consumer looks to buying
quality products that are attractively
packaged for hygiene and safety. This
can be ensured by using robotics in
packaging. With the introduction of new
robot system technologies, manufacturing
is continually undergoing major changes.
One area, in particular, where measurable
savings are seen is in the automated
palletising of products in all shapes, sizes
and weights.
Khalil Nathani, General Manager-
OEM, Rockwell Automation India
Pvt Ltd, says, “In order to differentiate
their products, manufacturers need to
continuously innovate, which is impacting
their product life cycles. Globalisation
has thrown in several competitiveness
challenges. Also, a surging middle class
is driving demands, and manufacturers
have to continuously scale up to seize this
opportunity. Manufacturing assets that are
highly productive and versatile to adopt
changing products are the order of the day,
and packaging industry is no exception
to this. Speed, accuracy/consistency,
flexibility to manage a variety of products
are some of the common requirements
across all packaging machinery. Thus,
automation and robotics play a pivotal
role in meeting all these requirements
of modern manufacturing industries to
enhance their business performance.”
Robotics in packagingRobotic palletisers have evolved rapidly
over the last few years. Nathani avers,
“Earlier, robots were used only to
perform high-speed repetitive tasks to
increase productivity. But, the evolution
of vision systems and precision actuation
systems, and the convergence of these
technologies with kinematics have
impacted the intelligence and application
of robots across various industries. Further,
flexibility in selection of pay load, reach
and duty of the robotic arm combined
with integration of vision system and
selection of choice of end effector has
opened up tremendous application
avenues in packaging, as they handle
infinite possibilities of product types
and the need for orientation of product
in packaging process. Further, reduced
cost of acquiring the robotics technology
44 Modern Packaging & Design July-August 2012
MACHINERY: Robot ic pal let iser
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Modern Packaging & Design July-August 2012 45
is opening commercial feasibility for
numerous applications.”
Advantages of roboticsRobotic palletisers alleviate the need
for manual stacking of bags, cartons or
drums onto a pallet. These are also used
for increasing end-of-line productivity
and improving the presentation of stacked
pallets. These are suited to applications
involving production from one, two or
more lines where flexibility is required
and space is premium.
In most cases, a robotic palletiser
provides a better alternative to manual
palletising technology due to many factors
such as increased output, continuous and
automated monitoring of operations,
safer working environment, less damage
due to smoother bag handling, flexibility
to handle a large range of products,
adaptability to new processes, reliability
and measurable Return on Investment
(ROI) within two years.
Nathani notes, “Robotic palletisers
offer flexibility to change form and
matrix of product to be palletised with
least effort, thus ensuring flexibility to
pack a variety of products with the lowest
downtime to set the machine for product
change. Further, higher throughput can
be achieved as a result of optimum path
control algorithms and higher speeds of
operation. The robotic palletisers also
ensure consistent delivery with high
precision and ensure best-quality packing
and reduced product rejections.”
Productivity enhancementIn the last few years, the flexibility,
speed, payload and reach of the robots
has increased, and this has resulted in
increasing the productivity. Nathani
says, “Advanced optimum path control
algorithms enable robots to travel
optimally from one point to another with
coordinated movements of multiple axes
with the shortest path, which reduces
the stroke length and, in turn, the cycle
time for every pick & place. Moreover,
the use of high-speed AC synchronous
motors ensures faster traversing speeds,
further reducing cycle time. This helps
manufacturers to produce more in
the same time, thereby impacting the
efficiency of their manufacturing asset.”
Better precision and safetyOf all benefits offered by a robotic
palletiser, precision and safety assumes
much importance. Nathani notes, “Robots
use multiple close-loop AC Synchronous
motors working in coordination to
achieve a motion. Close loop motor offers
capability to control the position precisely,
ensuring that the product is placed on
the pallets accurately in a programmed
matrix consistently. Further, advancement
in actuation technologies has generated
capability in the end effectors, which
grip the product to apply precise pressure
consistently to avoid any damages to
the product. Also, a vision system adds
visualisation capability to orient the
product and place it in a desired order on
consistent basis.”
He adds, “Manufacturers strive for
risk-free work environment by ensuring
safety to human, asset and product.
Modern control systems used for
controlling the robots integrate safety
control features such as safe off, safe
speed and safe networks ensure all safety
requirements for a safe & productive
manufacturing environment.”
Solutions for efficiencyWith advancements in robotics in the
21st century, many packaging companies
are turning towards the use of a robotic
palletiser. The obvious benefit is an
improved efficiency, and therefore, greater
profit. The robotics has been specially
modified to approach the high-speed
performance of conventional palletisers.
Based on the robotic palletiser’s ease of
operation, flexibility and repeatability,
it can become a key factor in a plant’s
ability to achieve the objectives of their
project. The only requirement is having a
trained systems integrator on staff with a
background in robotics. The preliminary
difference in the cost of the two systems
(robotic versus non-robotic) is rapidly
moderated by the repeatability, accuracy,
handling of products and reduction in
on-going operating costs, making the
robotic palletiser an obvious choice.
Future trendsThe usage of robotics in palletising will
definitely increase in the future. Nathani
concludes, “As manufacturers adopt highly
productive technologies such as robotic
palletisers, their next challenge will be to
integrate this highly capable machine with
proceeding and succeeding machines in
the line to impact the overall equipment
effectiveness. The line balancing system
needs to provide capability to avoid flooding
and starving of products by controlling
the in feeds to individual machines by
using advanced control algorithms. This
is expected to reduce wear and tear due
to sudden starts & stops of machines,
running the machines to match with
optimum line speed requirements,
thus saving energy and creating
a greener footprint.”
Email: avani.jain@
infomedia18.in
Modern Packaging & Design July-August 2012 45Modern Packaging & Design July-August 2012 45
Khalil NathaniGeneral Manager-OEM, Rockwell Automation India Pvt Ltd
Earlier, robots were used only to perform high-speed repetitive tasks to increase productivity. But, the evolution of vision systems and precision actuation systems, and the convergence of these technologies with kinematics have impacted the intelligence and application of robots across various industries.
MACHINERY: Conveyor technology
With line control and automation gaining importance in the beverage packaging industry, integrated conveyor technology has received much attention in the present scenario. Avani Jain takes a closer look at efficient conveyor technology and its advantages of speed and flexibility.
Mobility simplifies and
improves our everyday
life. Similarly, conveyor
applications keep the
industry moving right along. Whether
used in a specific production process for
further processing, storage or delivery, the
focus is always the same, ie, conveyors
need to span the distance efficiently and
transport items as quickly as possible from
one point to another. A reliable conveyor
technology is the backbone of efficient
packaging. So critical is its role that it can
be compared with the structure of human
body, where conveyors act as the arteries
and veins of the production line and the
filler is the ‘heart’ of the system.
Moving along the beverages segmentThe conveyor technology assumes much
importance in packaging, especially
beverage packaging industry. If utilised
correctly, it can be exploited to raise line
efficiency to a whole new level. Over
the years, many developments have been
made in the conveying systems so as to
ensure flexibility and speed.
Eike-Sebastian Hagen, Executive Vice
President-Operations, KHS Machinery
Pvt Ltd, says, “The choice of right
conveyor system is essential to achieve
the required line performance. Only
the correct conveyor layout with proper
buffers allows line running at its highest
efficiency. Hence, the correct conveyor
system is not a question of advantage or
disadvantage, but it is essential for the
required line performance.” He adds, “In
the beverage industry, we use container
conveyors [with belt or air conveyors
for empty Polyethylene Terephthalate
(PET) bottles], pack conveyors and pallet
conveyors. All these conveyors connect
the individual machines of a beverage
line. Furthermore, conveyors work as a
buffer to ensure that the line still runs
in full speed when one of the integrated
machines runs with a lower speed for a
certain period.”
Evolution of the technologyOver the years, conveying systems have
undergone various changes. Hagen
notes, “At present, conveyors run with
low energy consumption thanks to
variable centralised or decentralised
drive concepts with high-efficiency
drives (premium efficiency). At KHS,
we also design low-noise conveyors.
Advancements have also been made
in developing conveyor systems for
conserving resources with intelligent,
energy-saving belt lubrication systems.
Further, lot of changes are being
made to ensure that the operation of
conveyor systems can be consistent
and practically maintenance-free. Also,
long-lasting conveyor systems have
appeared in the market, thanks to stable
46 Modern Packaging & Design July-August 2012
Conveying flexibility and speed
MACHINERY: Conveyor technology
Courtesy: KHS GmbH
48 Modern Packaging & Design July-August 2012
design and high-quality materials used
in their manufacturing.”
One solution for multiple issuesThe use of integrated conveyor
technologies offers numerous benefits and
is equally important to address many of
the general production issues and trends
pertaining to packaging line changeovers.
The larger-scale obstacles that can be
addressed with conveyor add-on solutions
include new packaging technology, new
packaging materials and just-in time
inventory management.
With regard to changeover efficiencies,
the conveyor plays a crucial role of
transferring products from one location
to another effectively, without causing
harm to the product or workforce in the
process. In the converting operation, there
are many ways by which conveyors can
aid processors in reducing changeover
times. From an economic point of view,
automation of conveying operations
enables packaging solution providers to
achieve the required throughput volume
and competitive consistency. Advanced
monitoring and control capabilities enable
them to maintain higher up-time for their
packaging lines and reduce packaging
waste, energy consumption and rejected
packages. An ergonomic design enhances
worker safety and reduces repetitive
motion injuries and other hazards.
Enhancing speed and flexibilityConveying means transporting goods or
products horizontally or vertically from
one place to another. When spanning the
distance, the goal is to move the objects
as quickly and reliably as possible since
transport time is actually unproductive
time. Personnel safety is another
important issue. If the conveying process is
integrated into a uniform operator control
and automation system, it is possible to
achieve a markedly higher throughput at
the end of the line.
Hagen details, “All processes and
components in a turnkey system must
mesh perfectly to enable the machines
to run at optimum ability. The integrated
conveyor technology can help arrange
the production to avoid inefficient
stop-and-go operation in the filling or
packing line and enable maximum system
performance while, at the same time,
minimising machine stoppages.”
He adds, “KHS provides conveyor
systems in a modular design. This allows
us to provide the perfect layout for any
customer and react flexibly to individual
demands of each customer. The correct
design of the line layout allows the
customer to run his line with maximum
flexibility and highest efficiency.”
Improving line efficiencyThere are two essential considerations
for achieving good line efficiency. One is
through the design of the conveyor layout
as a people-friendly design essentially
manages man and material movement
& reduces stress for operators, while a
machine-friendly design layout helps in
supplementing machine performance.
Further, the conveyor technology is
important for line control and modulation.
Line control and programming takes
into account different scenarios based
on inputs from performance of the
machine and sensors placed at key points
throughout the line.
Hagen details, “Only components that
are perfectly aligned with each other can
turn the sum of individual machines into
a reliable and, above all, high-performance
and energy-efficient system. Acting as
a reliable link between the individual
production machines, conveyors provide
continuous and flexible supply of the
required containers. Combined with a
specialised system control that helps to
configure the production in order to avoid
an inefficient stop-and-go operation,
the conveyor systems developed by our
company helps in achieving maximum
performance with minimal machine
downtime.”
Imparting total excellenceA correct conveyor system design
allows the bottler to reduce downtime,
rejections, maintenance cost in spares
and high wear & tear of parts. It gives
bottlers the opportunity to truly automate
their line, thus minimising the number
of operations. Further, good conveyor
systems help in achieving greater
productivity and increased profitability
with an integrated product portfolio and
comprehensive solutions. These help in
lowering operating costs through targeted
minimisation of energy requirements. All
these finally equate to a sizeable savings
for the business.
Thus, conveyors as a total system can,
and is, as complex and equally rewarding
as any other packer machine on any
other line. Hence, bottlers must ensure
that it always flows smoothly. This can be
done seamlessly using the correct design,
materials and smart programming.
Future trendsThe future trends would include
decentralised control systems to ensure
that the customer can arrange each
individual transport segment separately,
and that the customer has flexible control.
Also, conveyor systems designed for
optimum cleaning, with different hygiene
designs that can adapt to all requirements,
would be another trend that will surface
in the time to come.
Email: [email protected]
Eike-Sebastian HagenExecutive Vice President-Operations, KHS Machinery Pvt Ltd
The choice of right conveyor system is essential to achieve the required line performance. Only the correct conveyor layout with proper buffers allows line running at its highest �����������
Conveyor technology
MACHINERY: Inter face - Avra Mitra
Modern Packaging & Design July-August 2012 49
“The world leaders in flexible packaging machinery segment are entering India”
…opines Avra Mitra, Senior Manager-Key Accounts, Business Unit-Web Fed, Bobst India Pvt Ltd. In a candid conversation with Avani Jain, he underlines the growth and opportunities for the flexible packaging machinery segment in India, as well as the recent trends and challenges.
How is the demand for flexible packaging/converting machinery in India?With the demand for flexible packaging
increasing in all segments of population,
demand for primary flexible converting/
packaging machines is growing constantly
in double digits. Due to various economic
opportunities, which are enhancing the
purchasing power of people, they are now
buying from retail outlets demanding
small sachets of oil and ghee, biscuit
packets, etc. These sachets and pouches
are a part of flexible packaging. This
is one of the factors indirectly driving
the demand for flexible packaging and
the allied machinery segment in India.
Further, the increasing disposable income
of the rising middle class has increased
the demand for flexible packaging.
The growth of processed food
industry has propelled the growth of
flexible packaging market in India.
Another factor driving industry growth
is the fact that per capita consumption of
flexible packaging is still lower in India
as compared to other countries such as
the US. Thus, there is a long way to
go and the future of flexible packaging
machinery segment is bright, although
few negative factors such as a ban on
plastics usage in packaging of chewing
tobacco will only affect one type of flexible
packaging and machinery market. For
the rest, there will be no change and the
demand for flexible packaging machinery
will increase significantly.
What are the recent trends in this segment?In terms of flexible converting/packaging
machines, companies today are set to shift
from conventional technologies to digital
printing machines for flexible packaging.
Another trend is that all leading
technology providers are developing new
technologies for energy optimisation
in primary machines. Companies are
also trying to move towards building
energy-efficient systems for their
machines. They are working on recycling
of solvents and making the machines
more compact.
What are the opportunities and challenges in this segment?The increase in domestic demand for
flexible packaging is driving the growth
of the flexible packaging machinery
segment in India. Lower cost of labour
is also a plus point. Today, the world
leaders in flexible packaging machinery
segment are entering India and starting
new projects or plants in the country.
They are either starting a subsidiary or
forming a joint venture to establish their
operations in India. These companies are
also bringing with them new technologies
and experience. Medium-scale enterprises
in flexible packaging are also investing
in new technologies and machines and
moving up the value chain.
Fluctuation in the prices of raw
materials, such as polyester, biaxially
oriented polypropylene and polyethylene,
is indirectly affecting the flexible
packaging machinery business. Lack
of skilled manpower to operate these
machines effectively is another concern.
What is the future of the flexible packaging machinery segment?Looking at the current trends such as
consistent growth of the processed food
industry, flexible packaging is the cheapest
& most convenient form of packaging.
This will drive the demand for flexible
packaging machinery. Also, with foreign
direct investment in retail, the demand
for flexible packaging and the allied
machinery business will further increase
exponentially.
Email: [email protected]
MACHINERY: Inter face - Avra Mitra
50 Modern Packaging & Design July-August 2012
“The demand for total quality solutions is increasing”
How is the demand for packaging machinery, especially in the beverages sector in India?The Indian market is growing at a rapid
pace, particularly the beverage sector.
Each segment of the beverage sector, ie,
water, juices, soft drinks and beer, has seen
double-digit growth in the last 4-5 years.
Thus, there is volume growth, which
means that the business of beverage
packaging machinery is promising.
Further, the food industry is growing at a
fast pace, and this is boosting the growth
of the allied packaging machinery.
What are the key growth drivers for the industry?The major growth driver of the packaging
machinery industry is the demand for cost-
efficient technology, with strong project
management. All players in the food and
beverage sector are currently looking for
single-window solutions where they can
give complete project to one provider
along with full responsibility for execution.
This phenomenon will become more
prominent in future. Hence, companies
in single machine manufacturing will
have to graduate to the level of providing
total solutions in terms of technology,
operational capability, installation/
commissioning project management,
troubleshooting, etc. Thus, the packaging
machinery manufacturers are looking for
indigenous innovations and international
partners to provide such solutions and
execution capabilities at lower costs.
What are the leading innovations in the sector? With regard to various segments in the
beverage sector, eg, soft drinks, we are
looking at some revolutionary solutions
in the Polyethylene Terephthalate
(PET) space, eg, light-weighting, high-
productivity machinery, etc. Further,
aseptic packaging of juices is now done
in paper cartons, ie, tetra packs. Soon,
we will see ultra-high temperature and
flavoured milk in plastic bottles. The
beer industry has undergone a revolution
in using light-weight glass bottles, thus
increasing the brew house production
capabilities, thereby increasing capacity of
their packaging lines from 18,000 bottles
per hour to 36,000 bottles per hour.
A lot of changes are happening in the
spirits industry, with decoration of bottles
gaining importance. Thus, each sector is
expanding in terms of variety of products
available and solutions. These changes
are driving innovations in the allied
packaging machinery industry. Thus, the
packaging machinery industry must look
into these aspects and provide innovative
solutions that are durable and economical.
What are the challenges facing the packaging solutions provider?The demand for total quality solutions
approach is a challenge for packaging
machinery providers who have to pay more
attention to quality and workmanship of
machines. They also have to compete with
international players like China, Italy and
Spain in terms of degree of automation &
reliability of machines.
What are the recent Research and Development (R&D) initiatives in your company?We align ourselves with our global R&D
capabilities. We are constantly involved
in providing technologies, which are
demanded by the Indian market. We are
currently developing the aseptic packaging
technology for milk, which will be on
ground by 2013. We are also looking
at high-capacity packaging solutions
for various segments in the beverages
sector, besides developing form-fill-seal
technology for powders and liquids.
Email: [email protected]
…asserts Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd. In a tête-à-tête with Avani Jain, he highlights various growth opportunities for the beverage packaging industry in India, while underlining the need for innovative packaging solutions in the beverages sector.
MACHINERY: Inter face - Yat indra R Sharma
LOGISTICS: Packaging for cold chain
India’s logistics infrastructure, particularly its cold chain industry, has caught the attention of the packaging sector owing to a surging retail industry. As Indians demand better quality fresh foods and ready-to-eat meals on the retail shelf, Annabel Dsouza probes packaging solutions complementing conventional cold chain systems in India.
Innovations for effective storage and transport
Packaging has a significant
impact on the efficiency and
effectiveness of retail supply
chains, where efficiency can
be achieved through adaptation and
development of packaging solutions that
are compatible with logistics systems.
Packaging also affects supply chain
effectiveness because it represents an
interface between the supply chain and
its main customer. This is especially
evident in complex supply chains,
which are fast putting fresh foods and
perishables onto the retail shelf. Fresh
and ready-to-eat convenience food
products are an emerging trend in urban
Indian lifestyle. Products such as pre-cut
fruits & vegetables and ready-to-cook
meals require an intricate cooling chain,
exclusive distribution within a limited
regional area or the use of Modified
Atmospheric Pressure (MAP) technology.
Although processed and packaged food is
highly popular in the Indian retail space,
the industry has to ensure futuristic
processing and packaging solutions for
quality & safety of the end-user. To
ensure that products are not damaged
or compromised throughout this retail
supply chain, the food and pharma
industries are increasingly adopting cold
chain technology.
RVS Ramakrishna, Group President–
Signode India, China & MEA, ITW
India Ltd, says, “Cold chain logistics
system may be defined as a series of
inter-related facilities for maintaining
ideal storage conditions for perishables
from the point of origin to point of
consumption in the food supply chain.
The chain starts at the farm level (harvest
methods, post-harvest and pre-cooling)
and continues till the consumer or
retail level. A well-organised cold chain
reduces spoilage, retains the quality
of harvested products and guarantees
cost-efficient delivery to the consumer.
And, packaging forms an integral
component of the cold chain industry.”
Cold chain technologyTemperature control in the shipment of
foodstuffs is a component of the industry
that has continued to rise in sync with
international trade. As India focusses its
export economy on food production, the
need to keep these products fresh for
extended periods has gained importance.
Increasing income levels create a change
in diet and a growing appetite for fresh
fruits and higher value foodstuffs such
as meat & fish. Ramakrishna highlights,
“With increasing purchasing power
among India’s surging middle class,
52 Modern Packaging & Design July-August 2012
LOGISTICS: Packaging for cold chain
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Modern Packaging & Design July-August 2012 53
RVS RamakrishnaGroup President–Signode India, China & MEA, ITW India Ltd
Ever since its advent in India, packaging logistics has been typically dominated by small players. While it has received a lukewarm response from almost all sectors, the food and pharma sectors have welcomed innovations in packaging logistics, and have bolstered low investment in cold chains & allied machinery.
Modern Packaging & Design July-August 2012 53
individuals with higher socio-economic
status and more economic means are
likely to consume vegetables and fruits,
particularly fresh, not only in higher
quantities but also in greater variety.”
A core component of the success of an
ideal cold chain is the type of container
used and the refrigeration method.
Factors such as duration of transit, size
of shipment and ambient or outside
temperatures are important in deciding
the type of packaging required. These
can range from small insulated boxes
that require dry ice or gel packs, rolling
containers, to large plastic trays with
self-sustaining powered refrigeration
unit. Some major cold chain packaging
technologies are:
Dry ice: Solid carbon dioxide, is
about -80°C and keeps a shipment
frozen for an extended period. It is
used for shipping of pharmaceuticals,
dangerous goods and foodstuffs. Dry
ice does not melt, but sublimates upon
contact with air.
Gel packs: Large shares of
pharmaceutical and medicinal
shipments that are chilled products,
must be stored at 2-8°C. Common
method to provide this temperature
is by using gel packs, or packages that
contain phase-changing substances
that can convert from solid to
liquid and vice versa to control an
environment. Depending on the
shipping requirements, these packs
can either start off in a frozen or
refrigerated state. Along the transit
process, they melt to liquids, while
simultaneously capturing the escaping
energy and maintaining an internal
temperature.
Eutectic plates: Its principle is
similar to gel packs. Instead, plates
are filled with a liquid and can be
reused many times.
Liquid nitrogen: An especially cold
substance, of about -196°C, used to
keep packages frozen over prolonged
periods; mainly used to transport
biological cargo such as tissues and
organs. It is a hazardous substance for
transportation.
Quilts: These are insulated pieces
placed over or around freight to act as
buffer during temperature variations
and to maintain the temperature
relatively constant. Thus, frozen freight
will remain frozen for a longer period,
often long enough not to justify the
usage of more expensive refrigeration
devices. Quilts can also be used to
keep temperature-sensitive freight
at room temperature, while outside
conditions can substantially vary.
Reefers: It is a generic name for a
temperature-controlled container,
which can be a van, small truck, a
semi or a standard ISO container.
These containers, which are insulated,
are specially designed to allow
temperature-controlled air circulation
maintained by an attached and
independent refrigeration plant.
The road ahead for IndiaThe proportion of products packaged for cold
chain systems at Indian ports has constantly
increaseddue to various trade liberalisation
policies, increasing containerisation in
general cargo commodities such as durables,
engineering components, machinery, auto
components, food products and apparels.
Value-added goods are expected to increase,
which will enhance the need for more secure
containerised transport. Containerised
transportation will also be driven by rising
international trade, increasing investments
in port infrastructure by the Government
and through Public-Private Partnerships
(PPPs). The cold chain industry is also
expected to grow at double-digits owing to
organised retail and growth in the processed
food sector.
Ramakrishna concludes, “Ever since
its advent in India, packaging logistics
has been dominated by small players with
small capacities and poor deployment
of handling, stacking & monitoring
technologies. While it has received a
lukewarm response from almost all
sectors, the food and pharma sectors
have welcomed innovations in packaging
logistics, and have bolstered investment in
cold chains & allied machinery.”
Email: [email protected]
Cou
rtesy
: LIN
PAC
Pac
kagi
ng
LOGISTICS: Reverse supply chain
54 Modern Packaging & Design July-August 2012
As the Indian industry realises the advantages of reverse logistics for cost efficiency and sustainability, Annabel Dsouza takes a closer look at innovative packaging designs that are playing a vital role in the success and commercial viability of this concept.
As innovations in the
packaging industry evolve
with the demands of the
Indian consumer, a leading
trend is sustainability and resource
conservation. Reverse logistics is among
the most important practices that is
driving innovations in the world of
logistics. Reverse logistics can be defined
as the process of planning, implementing
and controlling the efficient, cost-
effective flow of raw materials, in-process
inventory, finished goods and related
information from the point of origin
to the point of consumption in order
to conform to customer requirements.
Packaging and logistics have a long-
standing relationship and contribute to
innovations and commercial viability
of one another. In the field of reverse
logistics, packaging plays a critical
role during asset collection. Whether
consumers are shipping goods back to
the manufacturer for return, repair or
end-of-life disposition, packaging plays
an important role in reducing the risks
of damage and theft.
Reverse logistics is more than
just reusing containers and recycling
packaging materials. Remanufacturing
and refurbishing activities may also be
included in the definition of reverse
logistics. Redesigning packaging to use
less material or reducing the energy
and pollution from transportation are
important aspects of the reverse logistics
supply chain.
Profits through packagingJoseph Ringwood, Chief Operating
Officer, Systech International, says,
“With the credit crunch putting
pressure on the bottom line, packaging
manufacturers are adopting the practice
of Returnable Transit Packaging (RTP).
This is particularly true for defective
or end-of-life electrical and consumer
goods, which are quickly lost or become
obsolete in the return supply chain.
This minimises the opportunity to
return them to the market place and
forces them into global markets with
long and complex distribution networks,
or even, into the scrapheap. To what
extent businesses are able to recover
from these potential losses depends
on the speed and effectiveness of their
reverse logistics management.”
It is estimated that as much as
70 per cent of the potential market
value of these goods is lost as a result
of poor management. This level of loss
in the return supply chain is clearly
not acceptable in the current economic
climate, especially since it is easily
preventable. Here, packaging plays a
vital role in optimising efficiency. This
calls for packaging systems that are:
Locked to ensure against theft
Sealed for quick visual inspection
for signs of tampering
Serialised or bar coded
54 Modern Packaging & Design July-August 2012
Opening avenues for reusable packaging
LOGISTICS: Reverse supply chain
Courtesy: LINPAC Packaging
Reverse supply chain
Configured with sufficient padding
for laptops, CPUs or other data
devices sent on site ahead of pickup
for either do-it-yourself packing or
for a service to prepare assets for
shipping
A package change may occur due to
archaic design, or a change in the size
of the product. This is particularly true
with grocery items, where customers
may be conditioned to a specific price
for the product. Rather than increase
the price of the package, manufacturers
may keep the price constant by
reducing the amount of product in
the package, keeping the size of the
packaging unchanged.
Reusable corrugated packaging The efficiency of a successful return
supply chain depends significantly on
the usage and impact of transportation
packaging, pallets, drums, corrugated
boxes, etc. Although sustainability is a
cause of concern, returnable transport
packaging offers more economic
benefits than conventional methods.
Reusable containers are generally more
expensive than single-use packaging.
However, if a reusable container is reused
multiple times, the per-trip cost of the
reusable container quickly becomes less
expensive than the disposable packaging.
Corrugated containers are light-weight,
strong, easy to handle and inexpensive
and have set the standard for all other
packaging designs. However, the
corrugated packaging industry in India
finds itself at the crossroads. Increasing
prices of kraft paper, non-availability
of international standard papers at
affordable prices, resistance of corrugated
box user industry to offer sustainable
prices, increasing competition, non-
viability of automatic plants are proving
to be hurdles in the growth path.
Despite these adverse circumstances,
the industry is at an advantage in
overcoming India’s advancements in
reverse logistics. As global companies
set up their manufacturing bases in
India to meet the growing demand for
consumer and white goods, the need for
high-quality boxes is evident. Progressive
corrugated manufacturers are setting
up automatic board/box-making plants
to increase production and enhance
performance of boxes. In-house printing
on corrugated board is becoming an
imperative.
Advantages of returnable packagingOne of the major reasons why companies
consider reusable transport packaging is
to save on the purchase and disposal
costs of disposable packaging. In
addition to a lower per-trip cost, reusable
packaging may provide better protection
for the products being shipped. It also
provides the user with considerable
future flexibility. Transportation costs
are a major stumbling block to reusable
containers, as these tend to be heavier
than the corrugated materials that these
replace. Ringwood asserts, “Because
shipping costs can be weight-related,
this translates into higher outbound
transportation costs. If trucks ‘weigh
out’, that is, they are filled to their
maximum weight limit, the extra
weight of reusable containers means
that fewer units can be put on each
truck, which also means higher shipping
costs. Reusable containers often offer
an ergonomic advantage over disposable
containers. Most collapsible plastic
containers offer a drop-down panel in
one side of the container.”
Given the high initial investment
required for reusable containers, being
able to get the containers back is critical.
If a reusable container programme is
designed to operate only within the area
near a facility, getting the containers
back is not difficult. Transportation
costs should not outweigh the material
savings from the programme. However,
if the partners are far-flung, the reverse
transportation costs may be prohibitively
high, and hence render the programme
uneconomical. Ensuring that the
containers are returned may prove more
difficult as the distance increases.
Forward turn As the Indian industry realises the
advantages of reverse logistics and
its implications on the packaging
industry, product manufacturers and
packaging convertors are striving to
overcome the hurdles in infrastructure
and policy making. With the multi-
directional supply chain as the focal
point for delivery, consumption and
packaging recovery is increasingly
becoming the consumers’ home. This
relationship has the potential to shift
economic, environmental and social
responsibility away from the industry
towards the consumer. Ringwood
concludes, “Industrial cooperation to
implement the right conditions at the
start of the packaging supply chain
will assist the consumer to act with
environmental responsibility. While the
efficient handling and disposition of the
returned product is unlikely to be the
primary reason on which a company
competes, the packaging industry can
make a competitive difference.”
Email: [email protected]
Joseph Ringwood��� ��q������� ����� Systech International
With the credit crunch putting pressure on the bottom line, packaging manufacturers are adopting the practice of Returnable Transit Packaging (RTP). This is particularly true for defective or end-of-life electrical and consumer goods, which are quickly lost or become obsolete in the return supply chain.
Modern Packaging & Design July-August 2012 55
LOGISTICS: Inter face - Frank Ol iver i
56 Modern Packaging & Design July-August 2012
How does packaging contribute towards an efficient supply chain network?In the past 15-20 years, cost-effectiveness
and environmental efficiency have
received much importance in corporate
decision making. In the field of logistics
packaging, be it industrial transportation
or consumer packaging, manufacturers
make crucial decisions in order to
determine the optimal packaging expenses.
This decision situation practically means
the one-way and reusable (disposable
versus returnable packaging) mechanism
between packaging systems. Globally,
businesses are trying to integrate the
difference between these two systems, and
there are unique peculiarities. We must
look at the factors effecting packaging
logistics not only to provide us with a
primary or definitive solution, but to
develop operative frameworks for optimal
practices. Environmental regulations
in the last few years have increased the
importance of efficient packaging and
logistics systems.
What are the recent packaging innovations in the logistics sphere?Following are some of the major criteria
for innovations in packaging logistics:
Shrinkage - Pilferage, physical damage
and theft
Packaging cost - Optimum packaging
levels, based on logistics conditions
Inventory - Effective labeling and
tracking for supply chain visibility
Green supply chain - Applying
the reduce–recycle-remove–renew
template
Yield levels - Product yield levels to
consumers at the consumption point
How can packaging be designed for sustainable logistics?The design safety factor that we currently
follow is at least 2-3 times higher than that
in other developed or developing markets
due to poor logistics conditions. This can
be improved by better investment and
logistics infrastructure.
Packaging in India is historically
designed for manual handling in a
multilayer distribution model. Once a
retailer-driven supply chain process evolves,
organised logistics service providers
will evolve and bring standardisation of
practices and investments in logistics
infrastructure. These will facilitate
bulk/palletised shipments and help
manufacturers optimise packaging design.
Logistics service providers will be able
to consolidate the minimum order
quantity at Stock Keeping Unit (SKU)
levels and aggregate the same from
different manufacturers through effective
milk run in clusters. Through effective
use of supplier relationship management
software tools supported by track and
trace tools, an effective retailer-driven
supply chain can be designed from the
current manufacturer-driven operations.
Shelf-ready packaging at source
in manufacturing lines is another
huge opportunity for removing pack
duplications. If done at the last mile close
to the retailer, this will help improve
kitting and bundling cost & efficiency.
The returnable, mix-load bulk packaging
solutions can be improved between
distribution centres and stores, thus
reducing packaging & handling costs.
How do you perceive the progress of Indian packaging industry in the global arena?India is a dynamic market for the entire
world across industries, particularly the
retail market and its growth implications
on advanced packaging. Owing to poor
infrastructure and capacity constraints,
Indian convertors have to adopt relatively
higher safety margins. However, as the
Indian consumer becomes more quality
conscious and less price-sensitive,
one can perceive immense growth
opportunities in terms of innovations as
well as volumes.
Email: [email protected]
“We must look at packaging logistics to develop operative frameworks for optimal practices”…asserts Frank Oliveri, Vice President-Marketing, Packaging Resources Group, MeadWestvaco. He highlights the intense synergy between packaging and logistics systems in order to deliver value throughout the retail supply chain, in an e-interview with Annabel Dsouza.
LOGISTICS: Roundtable
58 Modern Packaging & Design July-August 2012
A K Kohli Executive Vice Chairman, Vikram Logistic
and Maritime Services Pvt Ltd
The logistics industry in India is evolving rapidly and it is the interplay of infrastructure, technology and new types of service providers that will define this industry’s contribution towards economic development by reducing logistics costs and providing effective services. A key partner of the logistics sector is the bulk packaging industry. Logistics costs (inventory holding, transportation, warehousing, administration, etc) have been estimated at 13-14 per cent of India’s Gross Domestic Product (GDP). The logistics costs can be reduced through packaging innovations such as flexible bulk packaging and corrugated palletisation. Inadequate logistics infrastructure creates bottlenecks in economic growth. Effective logistics management can overcome the disadvantages in the short term, while providing cutting-edge competitiveness in the long term. This can be compensated by innovations in the packaging technology to adapt to the transient changes in Indian infrastructure.
While the crucial relationship between packaging and logistics operations has been established in recent times, the vibrancy of both industries in India depends on infrastructure developments. Annabel Dsouza takes a closer look at the challenges and opportunities before the Indian packaging industry owing to India’s fast emerging infrastructure.
Sandeep Singh Director-Operations,
CAS Packaging India Pvt Ltd
Logistics is a critical component relevant across agriculture, manufacturing and service sectors and has to be optimally managed for smooth functioning of production & distribution. With rising competition within these sectors, it has become even more important to enhance the efficiency of the system in increasing manufacturers’ competitiveness. Given India’s fledgling status in inf rastructure development, packaging innovations are a crucial value addition to the progress and prosperity of the logistics industry. The industry in India is dominated by the unorganised segment; the organised segment accounts for less than 10 per cent of the total logistics market in India. Various value adding services are available, such as packaging, labeling, cross-bundling, track and trace, which are common irrespective of the mode of transport, besides some special services such as express and cold chain systems.
Ian Heyting Operations Manager,
Packaging Logistics International
Packaging has a significant impact on the efficiency of logistics systems and activities such as manufacturing, distribution, storage and handling throughout the supply chain. However, many packaging-dependent costs in the logistics system are frequently overlooked by packaging engineers. The growth and competence of the global packaging industry depends on a two-pronged development strategy of converting innovations & dynamic logistics infrastructure. In shipping objects to another location, packaging ensures it arrives safely and intact. Irrespective of the medium of transport, ideal packaging depends on the product involved, nature of shipping and destination it is headed towards. The quality and durability of various packing materials used and the correct carton type & size will assure the client that there are no mishaps between sending and destination.
Packaging innovations compensate for lack of adequate infrastructure development in India and boost the competitiveness of the nation’s logistics industry. Bulk packaging innovations such as FIBC and corrugated palletisation will play a
pivotal role in delivering value at the end of the supply chain.
Editorial take:
How can the packaging industry overcome the logistic challenges posed by
Indian infrastructure?
Email: [email protected]
SAFET Y: Fresh food packaging
The consumer shopping dynamics in the urban scenario has changed, with consumers now looking for convenient as well as cost-effective food packaging solutions. Lionel Alva assesses how aseptic filling and sealing solutions are setting a new paradigm in retail.
Aseptic solutions for the retail shelf
With retail shopping
becoming the hallmark
of the urban consumer
lifestyle, there is a need
to look at a viable solution for food
packaging that allows it to remain on
retail shelves for a long time without
quality degradation. Especially for
delicately processed foods and fresh
food, it is essential to look at solutions
beyond canning or bottling.
While aseptic food packaging
solutions are more expensive than
conventional methods such as canning
and bottling, it has an advantage
because the process of sterilisation
allows the packaged food to retain the
colour, texture, taste and nutrition more
than it does when subjected to more
heat-intensive conventional methods
used in canning & bottling. The
products also offer more convenience,
not only because they can be stored
in the pantry unopened, but also
because leftovers can be refrigerated
in the same package without the risk
of spilling, discolouration or the ‘tinny’
off-flavours caused when oxygen reacts
with the metal cans.
“Aseptic packaging solutions
have lesser deterioration compared
to conventional processes such as
bottling and canning. While they
may be comparatively more expensive
to produce, they make up for it by
offering better food preservation
quality, while retaining the original
flavour and nutritional characteristics
of the food items. However, with the
advent of thin-walled containers, it has
become a far less expensive proposition
to produce high-barrier, multi-layer
films for aseptic packaging,” avers
Neelesh Atasniya, Chief Marketing
Officer, Avonflex.
Advantages of aseptic packagingAseptic filling machines are designed
to utilise minimal energy and ensure
pre-sterilisation of the food before
the filling process begins. The process
ensures that the flavour and nutritional
components of the packaged food are
maintained.
Following are the three main
advantages of using aseptic packaging
technology:
Packaging materials that are unsuitable
for in-package sterilisation are used.
Light-weight materials consuming
less space, offering convenient features
and low-cost materials such as paper
60 Modern Packaging & Design July-August 2012
SAFET Y: Fresh food packaging
Fresh food packaging
Modern Packaging & Design July-August 2012 61
Neelesh Atasniya��� ����{����� ������]��[
Aseptic packaging causes lesser deterioration as compared to conventional processes such as bottling and canning. With the advent of thin-walled containers, it has become a far less expensive proposition to produce high-barrier, ���������������� ���������packaging.
Modern Packaging & Design July-August 2012 61
& flexible and semi-rigid plastics can
be used gainfully
Sterilisation process of High-
Temperature–Short Time (HTST)
for aseptic packaging is thermally
efficient and yields products with
high quality and nutritive value
as compared to those processed at
lower temperatures for longer time
Extension of shelf-life of products
at normal temperatures by packing
them aseptically
The hygiene level of the packaging
machine also enables a product
shelf-life up to 12 months at ambient
temperatures. In a well-designed aseptic
processing facility, the monitoring should
include periodic environmental filter
examination as well as routine particulate
and microbiological environment
investigation and may include periodic
sterile culture medium processing.
Package structure and compositionAseptic packaging must not only
protect the product, but also maintain
its quality. Hence, the structure as well
as composition of aseptic packaging
are more complex and vary depending
on product application, package size
& type. Factors such as seal strength
and integrity, package shape, stiffness
& durability, as well as barrier
properties determine the choice and/
or combination of materials required.
Generally, to achieve all required
properties, aseptic packages incorporate
more than one material in the structure
that is assembled by lamination or
co-extrusion process.
Aseptic packagingAseptic packaging exposes food to
detrimental factors such as heat for a
shorter period than the conventional
methods such as canning and bottling.
This means that the food retains its
inherent qualities without losing the
nutritional value, colour, texture or
flavour. They are also more environment-
friendly since they consume lesser
material and the package can be easily
recycled. Moreover, the production
process consumes lesser energy as
compared to conventional methods, and
this bears special relevance where there
is an increased emphasis on reducing the
green footprint.
“Another important consideration
for fresh food packaging is logistics.
For items such as meat that should
be kept frozen, a strong cold chain
logistics must be in place. This means
that the food has to be kept in a frozen
environment right from the time of
processing to transportation and even
when it is stored on retail shelves. This
is an expensive proposition and the
latest technology in aseptic packaging
is being developed that will eliminate
the need to keep food in a frozen state
and allow refrigerated products to save
on logistics expenses,” asserts Atasniya.
This bears special relevance in
the Indian context because of the
varying climatic conditions and the
fact that India does not have a strong
cold supply chain in place. Moreover,
India’s packaging market is huge and
growing at a fast pace, and is estimated
to represent almost 10 per cent of the
global market in terms of unit volumes.
Flexible packaging comprises the bulk
of the packaging market, and aseptic
packaging is all set to drive this market
even further.
Future of aseptic packagingThe focus will be on commercialisation
of multiphase food products, aseptic
bulk packaging, development of new
validation tools (biological, chemical
and electronic sensors), developments
in heat exchanger design, rapid cooling
methods and development of new
filling & packaging equipment with
higher line speed. Research is also
focussed on developing novel packaging
materials and techniques for advanced
sterilisation. Aseptic packaging is the
preferred method for packaging on retail
shelves and technology augmentation
& innovation will serve to enhance its
prospects in this sector, particularly in
food logistics & storage.
Email: [email protected]
Criteria for aseptic packaging
materials Must be compatible with the product intended to
be packed and comply with applicable material migration requirements
Physical integrity of the package is necessary to contain the product and maintain sterility
Must be able to withstand sterilisation and be compatible with the methods of sterilisation
Must protect the product from oxygen and retain the aroma of the product
SAFET Y: High speed packaging l ines
62 Modern Packaging & Design July-August 2012
Courtesy: Shuttleworth Inc
India’s sporadic retail rise is pressurising packaging manufacturers to accelerate production, while enhancing capacity for market sustenance, besides innovating constantly. Lionel Alva assesses how fully automated packaging lines depict a shift in packaging production dynamics.
The need for high-volume
packaging product ion
bears resonance for the
manufactur ing process
in contemporary times, with Fast-
Moving Consumer Goods (FMCG)
volumes driving the countrywide retail
growth. Packaging operations are under
intense pressure to achieve production
and quality objectives, while reducing
costs, adapting to rapidly changing
schedules, maximising asset utilisation
and continually improving overall
performance. This can be achieved by
streamlining operations in high-speed
packaging lines, but the overall process
of troubleshooting, analysis and core-
level problem correction of performance
in packaging environments is a highly
challenging proposition.
Moreover, even if the entire
manufacturing process spans a large
number of operations, packaging
comprises a large percentage of the
overall manufacturing cost. Thus, it is
important to have a keen understanding
of the entire manufacturing process
down to its finer intricacies and the
packaging ecosystem, which includes
the materials, suitability of machines,
factory environment and atmospheric
conditions. Further, product design
considerations must be scrutinised
in a carefully in order to establish a
cogent and highly evolved & integrated
manufacturing setup that is streamlined
and considered a natural progression of
an established environment.
Key design considerationsA modern packaging line is a
combination of inf rastructure and
investment, complex machines, conveyor
belts, pipelines and people, all working
together to achieve the goal of packaging
specified products. The packaging lines
can be protected to some extent against
unexpected events by using the right
combination of machines and conveyor
speeds, besides occasional introduction
of production buffers along the lines.
This is the most effective production
contingency that can be adopted.
These production buffers are a core
element of a line design, although
these represent only a small part of
the total investment. This is because,
if dimensioned correctly and placed
appropriately, these will ensure the right
balance of the whole packaging line,
allowing contingencies to be absorbed
without impacting the final product
throughput. Submitting provisional
designs in the early engineering stages
of the packaging lines for performance
simulation can save considerable money
and time, and help prevent flaws in the
approach that remain undetected in
the various details of a typical project.
However, submitting actual performance
of a high-speed packaging line after
installation could be equally decisive to
62 Modern Packaging & Design July-August 2012
Challenging convention with quality inspection
SAFET Y: High-speed packaging l ines
High speed packaging l ines
Suresh ShirwalkarGeneral Manager – Research and �]��q������!����[�q��{
Quality is a key consideration in high-speed packaging line. Checking the packed product regularly helps in detecting errors in the machine caused by various factors. Temperature changes can give weight variation and improve machine performance.
Modern Packaging & Design July-August 2012 63
ensure that even the last bottle or can
delivered by this final design is actually
obtained f rom the line. Applying
performance simulation to buffer design
is a key factor to achieving success in
the engineering as well as improvement
process stage in the life of a modern
packaging line.
Suresh Shirwalkar, General Manager
- Research & Development, Shruti
Flexipack, avers, “For packaging line
manufacturers, particularly high-speed
automatic machines, it is important
that the customer requirements are
properly understood by the machine
supplier at the machine design stage.
The machine manufacturer must also
suggest improvement in the process
to customer, which can increase the
overall output and enhance the process.
Quality is a key consideration in
high-speed packaging line. Checking
the packed product regularly helps in
detecting errors in the machine caused
by various factors. Temperature changes
can give weight variation and improve
machine performance. An automatic
checking system checks the packed
product continuously and helps keep
variations under control.” He elaborates,
“The composition of raw material
used for packing is important in
high-speed machines. As the machine
speed increases, time for each operation
is reduced. Variation in raw material
properties can give variation in packed
product. The packing material supplier
has to give assurance for the raw material
supplied to customer. Training of the
machine operator and maintenance
team is important in high-speed lines.”
Challenges to conquerFor reliable packaging manufactures,
order fulfilment and supply chain
responsiveness are dependent on reliable,
efficient, high-performance packaging
operations. On a high-speed packaging
line, this becomes a particularly
challenging proposition. Owing to the
emphasis on faster lead times, every
minute that a line is down leads to
loss in production. The fast nature of
the operating setup leaves little time
for operators to carefully scrutinise the
cause of downtime. The manufacturing
process becomes daunting if it is not
well understood and also when used by
a new operator.
“Another problem is retention of
skilled labour, for example, once the
labour is trained sufficiently, he may
migrate to another organisation offering
a higher wage. Often, if manufacturers
go for substandard machinery just
because it is available at a lower price,
the entire production might suffer.
In the worst case scenario, it might
even get derailed entirely. That is why
machine quality is important. However,
at present, one can opt for better
technology, since the latest machines
have servo motors that are brushless and
do not require periodic maintenance.
Besides, the machines have diagnostic
screen that gives alarms and reasons for
machine stoppage; hence, eliminating
the need for constant maintenance as
long as the manufacturer realises &
fulfils the operating parameters,” asserts
Shirwalkar.
Speeding up performancePackaging is a complex endeavour
involving a matter of addressing
shape, size, materials and marketing
requirements quicker and with improved
safety. A manufacturer with a high-
volume production and an established
manufacturing process would do well
to opt for a high-speed fully automated
packaging line. The manufacturer must
bear in mind here that due quality
considerations must be in check since
unlike manual packaging manufacturing
or semi-automatic packaging lines,
there is a drastic change in approach
in high-speed packaging lines and even
slight deviations in material conditions,
quality or composition could deeply
affect the final product.
Weight and size considerations must
also be given due importance owing to
stringent regulations in place. However,
considering the burgeoning retail sector
that is a reflection of the country’s
economy moving towards a financial
crescendo, there is a need for a model
approach towards high-speed and
high-volume production in the current
scenario. When properly designed
and integrated in the desired manner,
such machines can give the packaging
manufacturer the required leverage
to position himself in a pragmatic
manner, while being available to market
opportunities despite demanding
requirements and dynamics.
Email: [email protected]: Multivac
SAFET Y: Inter face - Kr ishnamachar i Ravi
What are the major technology trends in the Indian packaging industry today?We are currently engaged in two verticals,
which include packaging in flexible bags
and drilling & sealing of pre-formed cups.
Today, the primary concern for the major
brands in the food industry is product
shelf-life. For food items
available in malls,
especially those that
need refrigeration,
a strong cold
chain refrigerated
environment must be
present throughout.
Therefore, right
from transportation to
storage of such items in
a retail setting, the
cold chain is
an important aspect. Moreover, fresh food
is stacked in a specific manner to achieve
the desired shelf-life. Aseptic filling and
sealing solutions are increasingly being
used. Another development is significant
growth and demand for pack sizes at
the lower end, especially in Tier 2 & 3
cities. Thus, the spending is on high
volume packaging machinery because
the Indian market is mainly driven by
price-point marketing.
What design parameters do you follow for building customised solutions?We avoid using a 100 per cent customised
design since it is a risky proposition.
There is a possibility that if the design
has not been tested in a factory setting
to a complete extent, the parts and
individual components may not function
in cooperation. Moreover, it needs a keen
scrutiny and minute factors may alter the
commercial viability of the prospect. It
heavily depends on customer changes
where we offer standardised design
and wherein modular engineering is
possible, thus providing a comfortable
middle ground.
How do you gauge client technology requirements?Our approach towards business is that
the customer will stay with us if we
offer a value proposition, which comes
through a keen understanding of their
business requirements. A market research
in India had indicated that more than
50 per cent of the packaging machinery
used in the country was considered a
failure. For a packaging machinery to run
successfully, it must have a combination
of primary aspects, which include the
machine quality, engineering expertise
and reliability of components. Attention
should be paid to the quality of packaging
material. As the process becomes more
automated, the tolerance for deviation
in material becomes narrower, and
slight deviations can influence product
characteristics. Site conditions must also be
given due attention.
How important is Enterprise Resource Planning (ERP) in the Indian context?ERP is extremely important in the Indian
context as the packaging industry is quite
small here. It is difficult to find an expert
in this field, and since the Indian industry
is growing fast, individuals from ancillary
industries are hired immediately. Further,
it is necessary that they quickly understand
the intricacies of the packaging business.
ERP is important here since everything
is listed out and enhances the learning
curve. It also expedites the routine
work, thereby streamlining the entire
packaging process.
What is the scope for your solutions abroad?We have a strong market abroad since
we have been exporting 30 per cent of
our output. Our clients are present in
several Asian countries such as Indonesia,
Pakistan and Sri Lanka. We are the
preferred supplier for several fast-moving
consumer goods companies abroad since
they require a good partner who offers
them solutions that are comparable to
the economies of emerging market and
also maximise value for the consumer.
Manufacturers should focus on ownership
cost rather than equipment cost.
Email: [email protected]
“Manufacturers should focus on ownership cost rather than equipment cost”
…asserts Krishnamachari Ravi, Managing Director, Hassia Packaging Pvt Ltd. He provides a unique insight into the varied nature of India’s packaging industry, while analysing the challenges and future trends. In an interaction with Lionel Alva, he highlights the growth prospects of this industry in India.
64 Modern Packaging & Design July-August 2012
SAFET Y: Inter face - Naushik Kabra
What is the potential of aseptic packaging solutions in Indian retail today? Aseptic packaging solutions are an
integral part of the Indian retail sector.
Aseptic packaging primarily consists of a
combination of three individual layers, ie,
paper, polyethylene and aluminium. This
combination of non-related materials
yields an outcome that is more than
just satisfactory in terms of maintaining
high levels of sterility and retaining the
nutritive value of the product that it
carries. A crucial advantage as well as the
primary objective of aseptic packaging is
that it preserves the product it packages
over a long period. Aseptic packaging
solutions have simplified our lives to an
extent where we could have a ready-to-
eat meal in less than a few minutes, as
they have been preserved and packaged
using such solutions.
What innovations do you consider as the most significant for the packaging industry today?With rapid growth in technology and
increasing competition, innovations are
integral for the consistent growth of any
industry. The packaging industry being
large in size and spread across the world
comes up with several innovations from
time to time. Not only are manufacturers
promoting these products and creating
awareness, but customers who use our films
to pack their products also specifically
suggest the application of these polymers
and films for their packaging.
A strong misconception is that the
use of biodegradable polymers might
decrease the required specifications and
quality parameters of the films produced
for packaging. We recommend the use of
biodegradable polymer films to replace
their existing packaging films at a low
or insignificant cost, keeping in mind
the benefit to society and indirectly
assisting the industry. The presence of
these polymers may induce the Indian
Government to rethink some of its harsh
decisions to ban certain plastics. Another
important innovation in the Indian
polyethylene industry is the development
of competitive quality of agri-films such
as greenhouse Ultraviolet (UV) films and
mulching films, which enable farmers to
grow flowers, vegetables and fruits with
better quality. These films allow only
the required amount of UV rays to pass
through and block all harmful UV rays,
and that too at competitive costs by
saving on water & pesticides.
What are the significant challenges for the packaging industry today?All industries face challenges in one
way or the other. Challenges could be
considered both negative and positive.
However, the key to face a challenge in
any industry would be to take it positively
and prepare to fight back. One of the
challenges before packaging industry is
acute shortage of timely supply of the
required polyethylene raw material in
the Indian market. This is also because
the industry heavily depends on a single
domestic manufacturer. Thus, we import
material from the Middle East and other
sources across the world in order to be
self-sufficient and not depend only on
domestic market supplies.
How do you see the future of the packaging industry in India?The future of all industries in India
along with the growth of the Indian
economy is positive. In particular, the
growth of packaging industry in the
last few years has been encouraging.
The key is to innovate and compete
in the global market, towards which
the Indian packaging industry is
currently heading.
Email: [email protected]
“The key is to innovate and compete in the global market” …asserts Naushik Kabra, Director, Synthetic Packers Pvt Ltd. He highlights some of the developments in packaging technology while assessing the key implications of economic development and offers insights into the future of the Indian packaging industry, in an interaction with Lionel Alva.
66 Modern Packaging & Design July-August 2012
SECURIT Y: Brand protect ion
The packaging industry is well aware that brand value may be attacked by product counterfeiting, parallel trading, product tampering and theft. Anwesh Koley looks into the various measures that provide protection to the brand image by employing the right checks and necessary actions.
Consumer confidence through package integrity
In a vast country like India,
packaging security has a pivotal
role to play in the purchasing
decision of a consumer. The
consumer of today’s India is a smart
buyer, well versed with global trends and
market information, immense product
knowledge and highly alert about the
product offerings. Consumers today are
demanding and aware of counterfeiting
threat across the globe.
Packaging securityConsumers are looking for a well
packaged product worth the money they
spend, and are seeking the assurance &
authenticity of the product purchased
without incurring additional costs.
Security features providing freshness,
safety and authenticity of the product
purchased is the customers’ expectation
from packaging.
Security benefits such as
anti-counterfeiting, tamper evidence,
track & trace and brand protection
features are integral to the packaging
industry. At the same time, the trend has
opened numerous opportunities for brand
owners who are increasingly looking to
leverage packaging as a differentiator.
Jitesh Mehta, Director Marketing,
Label and Packaging Materials South
Asia, Avery Dennison (India) Pvt Ltd,
avers, “The needs of customers have
led brand owners in segments such as
pharmaceutical, food, home & personal
care, white goods and automobiles to
leverage packaging as a tool to offer
security and brand protection features
along with the functional advantages.”
Further, brand custodians operating
in key segments are actively looking to
serve the rural market for better growth
momentum. Counterfeiting becomes a
major challenge for these custodians in
the rural market. Brand awareness is
trivial and customers tend to purchase
products relying more on visual appeal.
Hence, packaging security ensures
counterfeit products do not reach the
vulnerable rural consumers.
Counterfeiting is one of the world’s
fastest growing industries and is said to
represent an approximately $ 600 billion
market globally. It is a rapidly growing
business and it is the top priority for
Government and companies across the
globe to curtail counterfeiting.
Fraudulent products are easily sold in
the market, which leads to lost revenue
to the Government and brand owners,
while potential product safety concerns
68 Modern Packaging & Design July-August 2012
SECURIT Y: Brand protect ion
Cou
rtes
y: A
very
Den
niso
n
Brand protect ion
Modern Packaging & Design July-August 2012 69
Jitesh MehtaDirector Marketing, Label and Packaging Materials South Asia, Avery Dennison (India) Pvt Ltd
This is an opportunity for packaging companies to work as a team and meet the performance requirements of brand owners in terms of identifying unmet needs, being price competitive and offering commercially viable solutions.
Modern Packaging & Design July-August 2012 69
to consumers. “Such products destroy
brands by impacting the credibility and
brand equity in the market, and with
counterfeiters constantly on the look
out for new products and industries, it
is becoming a major threat for authentic
companies,” adds Mehta.
Growing faster than genuine
products, the global counterfeiting trade
has doubled in size in just five years.
Pharmaceutical, medical and cosmetics
industries pose a particular high risk
to the public among all industries. The
International Commerce Commission
(ICC) and Business Action to Stop
Counterfeiting and Piracy (BASCAP)
also estimated that by 2015, piracy
will grow to become a $ 960 billion
problem. “Brand protection is no longer
a luxury, but a business necessity. In
today’s market, we face brand piracy,
counterfeit goods, market diversion
and inf ringement of intellectual
property/ trademark assets in alarming
proportions,” believes Mehta.
Anti-counterfeiting solutionsSecurity labeling is an essential tool
for combating counterfeiting. Today’s
consumers look for overt security labeling
to visibly guarantee genuine products,
while covert and forensic solutions
deliver an extra layer of protection by
ensuring product integrity from the
producer to the user.
Therefore, brand owners need to find
new and effective ways to protect their
brand, customers, revenue and reputation.
The fragmentation within the label and
security technology supply channel is in
direct conflict with the brand owner’s
need for increased confidentiality, speed,
flexibility, chain of custody control and
secured site assurances coupled with
a wide range of security options. “In
times of tampering, counterfeiting and
shoplifting, no area is immune from
brand-damaging, sales-sapping activities.
Fortunately, there are spectrums of
safeguard options to protect products
from harm, keep brand equity intact
and put brand control back into brand
owners’ hands,” adds Mehta.
Security challenges While Government rules and regulations
on anti-counterfeiting have been
defined, they are not as effective, as
brand owners would like. This puts the
onus on the brand owner to incorporate
packaging security features to ensure his
product/brand safety. In an intensely
competitive and complex market like
India, the brand custodian needs to
provide effective security solutions to
ensure the authenticity of his product,
and that it reaches the consumer without
tampering. This may not be completely
fulfilled as manufacturers are bound by
cost implications.
Often, packaging development
managers face stiff resistance for upgrading
and investing in latest security solutions,
with only some incremental improvements
made in the conventional security solutions.
Typically, an effective security solution
is a combination of security product and
processes. “Highly specialised materials
with a complex printing process can
provide an excellent solution, which meets
the brand owner’s requirements completely.
This is an opportunity for packaging
companies to work as a team and meet the
performance requirements of brand owners
in terms of identifying unmet needs, being
price competitive and offer commercially
viable solutions,” opines Mehta.
Indian companies vis-à-vis global counterpartsGlobal packaging companies are
way ahead in terms of technology as
compared to their Indian counterparts.
The packaging companies serving the
developed markets are at a matured stage
in their learning curve, and this is through
their sheer exposure and experience. For
example, Radio-Frequency Identification
(RFID) solutions for track and trace
are rapidly accepted in the western
markets at the carton & unit level, but
such measures are at a nascent stage in
emerging markets like India. To sum
up, emerging markets are fast catching
up with their global peers in terms of
packaging security solutions.
Email: [email protected]
Key trends in the packaging
security domain Digital printing and water marking Sophisticated, covert holograms RFID identification at carton and
unit level (supply chain) Layering (overt, covert and track &
trace feature in a single solution)
Cou
rtesy
: Ave
ry D
enni
son
SECURIT Y: Package test ing equipment
70 Modern Packaging & Design July-August 2012
Courtesy: FedEx
Testing instruments play a significant role in ensuring strict quality norms laid down by global packaging standards. Anwesh Koley gauges the importance of package testing at every stage of the value chain, which boosts packaging excellence.
The market for testing
equipment has been growing
over the years and the
current situation is quite
positive. Gaurav Malhotra, Director,
Presto Stantest Pvt Ltd, says, “Earlier,
companies did not stress much on testing
equipment, but gradually the packaging
sector has become quality conscious,
which is helping them to minimise
transit damages. If the quality is checked
for top-load and drop test, then we can
ensure that minimum possible damage is
made to packages during transit.”
Packaging testing market in IndiaThe industry has developed numerous
specialised equipment, which simulate
the conditions a product experiences
during transportation. These include
vibration tables and drop testers at
specified height & angles. Top load
testers that gauge the crumbling load or
buckling load well in advance to check
the sustainability of the packaging.
Earlier, companies were reluctant to
invest in packaging equipment because
they thought they were well aware of
this requirement. However, now with the
advent of packaging testing equipment,
they have realised considerable cost
saving by reducing logistics damage
Today, companies demand special
purpose machines that are designed
according to their specific requirements.
These machines could be as simple
as a tester for the scrubbing load
of a label to test printing quality.
“There are equipment that record the
atmospheric conditions throughout the
transportation period of the material.
A data logger is kept in the shipment
along with the packages. This gives
an idea of the varied conditions that a
package has to undergo if the distance
is very large. There are software that
help in logging this data at different
time intervals,” adds Malhotra.
Innovations in testing industryCompanies now rely more on
automation as they do not want to risk
human error. Extensive computerisation
is required for this in order to reduce
time and provide faster feedback.
Earlier all data were recorded manually,
which increased the possibility of error,
whereas today, we can have all the
information available. The computer
interface does all calculations and can be
mailed through Ethernet. Auto-triggers
can be set, which help in conveying
information to the party whose package
is being tracked.
Earlier, most companies had
analogue burst testing equipment,
which provided the bursting strength of
a package as well as its Bursting Factor
(BF). This is based on the weight of
70 Modern Packaging & Design July-August 2012
Reducing in-transit losses
SECURIT Y: Package test ing equipment
Package test ing equipment
the package, which is measured in
Grams per Square Metre (GSM).
Today, the analogue instruments have
been replaced with computerised ones.
This yields the BF directly through
digital or computerised equipment.
The techniques remain the same for all
forms of packaging, be it plastics, metal
or glass, with minor modifications as
per specifications of the package and
its capacity.
Testing instruments are the only
means of checking for quality at all
three stages of manufacturing:
Incoming QC: It is related to quality
issues of raw material. If tested at
this stage, a sub-standard product
will not come into production at all.
In-process QC: This is related
to quality issues in the processing
stage. If tested at this stage, the line
can be halted and amends made to
ensure no further losses happen.
Final QC: It is related to quality
issues of the final product. If tested
at this stage, it ensures that a poor
quality product does not reach the
end customer.
Testing instruments can help in
significantly avoiding and decreasing
rejection, thereby saving millions.
India vis-á-vis global playersThe package testing industry in India
is at par with international standards
as far as technology is concerned. The
extent of growth achieved by Indian
testing equipment manufacturers has
been commendable. There are variations
in the testing equipment available in
the market. Essentially, the quality
of services provided and the network
span of companies determine market
dynamics. Indian testing equipment
players are receiving orders from big
multinationals for setting up testing
laboratories, which clearly shows the
eagerness towards testing equipment to
achieve global quality standards.
The Indian testing instruments
market is growing due to the realisation
that there is more to gain than lose by
investing in testing instruments. This not
only enhances and improves the quality,
but also ensures best value for money in
terms of right procurement. It is now
being considered as an investment rather
than an expense. “Our strength lies in our
ability to change and that too at a fast
pace. Automation will be the key to the
future as global levels of automation are
at present higher than that of India but
it would be just a matter of a few years
before we catch up” believes Malhotra.
Earlier, these multinationals opted for
imported testing machines only, as they
were sceptical about similar products
available from domestic manufacturers.
However, with awareness spreading fast,
they have seen similar results in quality
testing from domestic manufacturers as
well. This can be attributed to an efficient
service network offered by Indian
manufacturers. With the development
of technology, it is now seen that the
cost of a computerised monitor is lower
than a few analogue monitors available
in countries like Europe.
Testing timesWhile large companies have recognised
the importance of employing testing
equipment for packaging, we are yet
to see medium- and small-level players
take the initiative. Small vendors and
dealers find testing equipment as merely
a cost that does not yield much results or
returns, which is not true. “It is important
to ensure quality up to the last level till
the product finally reaches the customer,
and the vendors are an important part of
this value chain. Hence, the large players
in the industry must percolate the
advantages of package testing to the last
levels of distribution in order to retain
product value,” says Malhotra.
Email: [email protected]
Gaurav MalhotraDirector, Presto Stantest Pvt Ltd
It is important to ensure quality up to the last level till ������ �����������������the customer, and the vendors are an important part of this value chain. Hence, the large players in the industry must percolate the advantages of package testing to the last levels of distribution in order to retain product value.
Courtesy: FedEx
Modern Packaging & Design July-August 2012 71
SECURIT Y: Inter face - Kar l Vandenbussche
72 Modern Packaging & Design July-August 2012
“India is the place to watch out for in labeling technology in future”
What are your views on the package labeling industry in India?The Indian labels industry is complex,
dynamic and growing fast. Although the
per capita consumption of labels in India
is the lowest in any analysed region,
it has the highest growth rate in the
world, at 19 per cent. In India, wet glue
labels although still growing in double
digits, are fast making way for pressure-
sensitive and flexible film labels. The
bar-coded labels market is growing by
30-35 per cent in India. This industry
is making way for smart Radio-
Frequency Identification (RFID) labels
across the globe. Narrow web flexo and
combination presses are growing in
India as compared to growth of digital
label presses in advanced countries.
Wet glue has been dominant in
India because of its obvious ease of
production and simplicity in application.
Nevertheless, wet glue labels although
huge in quantity and with continued
double-digit growth were overtaken in
value but not in quantity, by pressure-
sensitive labels in 2003-04. In contrast,
the flexible, shrink and wraparound
labels form the highest growth segment
of the label industry (more than
24-25 per cent), but this growth is on a
small scale.
What is the key to ensure efficient labeling solutions for packaging?It all depends on the in-house prepress
where the latest systems must be installed.
This will give a head start printing plates
of unusual sharpness, detail and overall
consistency. The print offices should be
equipped with state-of-the-art presses
capable of combining several printing
techniques (eg, flexography, screen print,
hot and cold foil stamping) to obtain the
highest achievable result. If a labeling
company has efficient suppliers, it can
obtain the largest range of printable
materials and adhesives to tackle the
most difficult applications in the most
awkward conditions.
Modern consumer product marketing
believes that product packaging and the
label should be attractive enough to sell
the product on their own. This requires
high value addition that is associated
with the pressure-sensitive segment
and, especially, its new varieties such as
clear see-through pressure sensitive and,
in some cases, shrink-wrap labels. It is
estimated that flexible labels, pressure-
sensitive, wrap-around and shrink-wrap
labels, will rapidly take away marketshare
from paper-based labels. India has shown
huge potential in terms of labeling
solutions. It is a market that currently is
ready to be explored.
At Reynders, what quality control initiatives have you undertaken?All steps in the process are supported by
a Reynders Application System (RAS),
which is a software especially developed
for our group as per the pharmaceutical
standards in Europe that gives a common
platform to all production units in Europe
and India. This allows us to create unique
numbers for layouts and traceability of
all processes up to arranging automatic
communication with transport about the
amount of boxes, weight & address and
the communication between different
production units regarding concept labels,
materials and new developments.
It is important to have a high level
of quality control built on standardised
procedures to ensure complete detection
of non-conformities at every stage of
production. A final inspection with a
camera control will further eliminate
defaults not visible to the human eye.
Packaging is done with utmost care to
guarantee the integrity of products both
in transport and, later, when stored in the
warehouse.
What are the challenges facing the package labeling industry in India?The label industry is facing many small
hurdles that are hindering its growth. The
first is that the printing industry as a whole
has been unorganised and fragmented,
lacking investment in specialised
components & tools. There is a dearth
of technology, research and development,
standardisation, testing & certifying as
well as training facilities. Environment,
health, safety and best practices are some
of the issues that must be tackled for
the industry to address its customers’
needs. Foreign direct investment and
organised retail growth are the key
drivers for the packaging and labeling
industries.
Email: [email protected]
…opines Karl Vandenbussche, Director, Reynders Label Printing India Pvt Ltd. In an interaction with Anwesh Koley, he describes the latest in labeling technology for the packaging sector and the essentials to consider for a long haul in this market.
SECURIT Y: Inter face - Satyadeep Ray
Modern Packaging & Design July-August 2012 73
“Higher research will ensure that holography finds wide-ranging applications”
What is the status of the holographic packaging industry in India?In India, previously, packaging was
done primarily through the use of
polyester, coupled with simple printing
on the external packaging. With the
advent of holography, manufacturers
who faced the problem of duplication
adopted this technique. Holography
is a sophisticated technology using
laser optics. It can never be duplicated,
and thus provides vital security to
packaged products.
As holographic packaging emerged
in India, companies were assured of their
brand image and product authenticity.
Various holographic materials are used
as packaging materials, eg, holographic
packaging films, hologram hot stamping
foils, holographic aluminium foils,
hologram labels, hologram tape/security
tape, hologram stickers, etc. Holographic
packaging also improves the aesthetic
appeal of the product. It provides a higher
visual treat to the potential consumer
at the first glance as compared to
ordinary printing.
How does holography provide security to packaging? Earlier, companies used conventional
printing on laminates and pouches made
of polyester. Today, on the same material,
holography is used. Once the holography
is done, duplication of the product
becomes difficult, as it ensures a unique
identity to each product. Holographic
packaging is inexpensive as the procedure
involves embossing holographics on
polyester or other materials. Embossing
is a technique of applying heat and
pressure, which transfers the holography
from the metal plate to the polyester
material. It is marginally expensive than
ink printing but offers more advantages.
What are the advantages of this technology?Due to certain policies, manufacturers are
moving towards paper packaging instead
of plastics packaging in certain sectors.
Even in paper packaging, holography
is used through the same technique as
used for plastics packaging. Customer
perceives higher value addition, since
holography provides differentiation and
shelf appeal that brings product to the
front on the shelf. In this era, where
customers face the psychology of choice
everyday, holography helps attract the
attention of customers and move the
product off the shelf. This is because
holographic images can ‘move’ and ‘speak’
to consumers through optical motion,
and packages with holograms attract
attention of the customer.
What is the way forward for this industry?The large population of India ensures
that the demand for packaging products
is always on the rise. The problem
of duplication is high in India and
holography provides a vital solution for
tackling this menace. Holography can be
used on aluminium surfaces, paper and
polyester. This technology has already
entered the country and with the high
levels of research and development, we can
expect more enthusiasm from packaging
companies towards anti-counterfeiting.
However, the Government must be
lenient and flexible towards holography.
If this technology is made mandatory for
the relevant sectors, it will go a long way
in providing quality to the consumer as
well as preventing spurious products from
entering the market. This will increase
the revenue for manufacturers and, in
turn, for the Government. Similar to the
information technology sector, we witness
some new technology in holography
every year, which is another reason for
companies to adopt this technology.
Email: [email protected]
…opines Satyadeep Ray, Director, Holostik India Ltd. In an exclusive conversation with Anwesh Koley, he highlights the importance of holographic packaging in India where spurious products pose a constant threat to quality and consumer interest.
SUSTAINABILIT Y: Packaging mater ia l
With sustainability being one of the biggest challenges facing the packaging industry, downgauging packaging materials seems the most effective way for resource and cost reduction. Avani Jain looks at the current trends and methods adopted by companies in the segment for downgauging the packaging materials.
More value with less resources
Today, flexible packaging
solutions represent the entire
packaging industry. This is
primarily due to the benefits
offered by flexible films in terms of
relatively low cost, good barrier properties
against moisture and vapour, heat-
sealability, handling ease and convenience
for the manufacturer, retailer and
consumer. However, rising raw material
prices have led the plastics packaging
companies to move towards sustainable
packaging and explore the possibility of
downgauging the packaging materials for
cost & resource reduction.
Downgauging refers to reducing the
amount of material in a product, while
still maintaining or even improving the
material properties. For example, just
a few grams saved in the weight of a
package can have a tremendous impact
on the environment and lead to cost and
resource reduction when factoring the net
gain of millions of individual packages.
Today, manufacturers of packaged
goods are constantly challenged to reduce
packaging for cost and resource reduction,
while ensuring that it still serves the
primary purpose, ie, protect the contents
and help sell the product. Polyethylene,
the most widely used flexible packaging
material, has come a long way and
packaging engineers have capitalised
on designing flexible packages that are
thinner & lighter than ever.
Towards sustainabilityIn a study conducted by the Associated
Chambers of Commerce and Industry of
India (ASSOCHAM), it was found that
the rising concerns over environmental
hazards, carbon emissions, waste reduction
targets specified by different countries and
the trend towards green packaging are
some of the factors propelling companies
to take up the task of sustainable and green
packaging. The study further stated that
the green packaging industry is growing
at about 25 per cent per year, faster than
the overall packaging sector, which is
growing at about 20 per cent annually, thus
focussing on sustainable packaging as the
latest trend.
Current trends In keeping with the demand for
sustainable packaging, the packaging
companies are increasingly adopting
strategies to reduce the weight of product
packaging materials. Approximately
5.6 billion two-litre plastic soda bottles
are sold each year. When introduced in
the late 1970s, these weighed 68 gm or
less. Improved packaging technologies
74 Modern Packaging & Design July-August 2012
SUSTAINABILIT Y: Packaging mater ia l
Cou
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y: B
orea
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G
Packaging mater ia l
Modern Packaging & Design July-August 2012 75
Rajesh K PandyaVice President-Operations, Parikh Packaging Pvt Ltd
The future trends for conserving resources and reducing cost would include reusable packaging, elimination of secondary packing by developing sustainable inner/primary packaging, innovation in reducing number of layers in high-barrier laminates, thereby reducing material consumption, energy usage and production costs.
Modern Packaging & Design July-August 2012 75
have decreased the weight of the same
type of bottle to as low as 49 gm or less,
eliminating an estimated 200 million
pound of Polyethylene Terephthalate
(PET) each year. Also, plastic trash
bags began appearing in homes and
along curbsides around the world by
the late 1960s. Since that time, plastic
trash bags have been made thinner by
50 per cent, thus saving millions of pounds
of polyethylene.
Rajesh K Pandya, Vice President-
Operations, Parikh Packaging Pvt Ltd,
says, “In recent years, the weight of PET
mineral water bottle has also reduced
drastically, from 78-90 per cent to
28-32 per cent. In case of flexible
packaging, the film thickness has been
reduced by nearly 30 per cent than that
used until a few years ago. A decade
ago, the thickness of the film used for
packaging milk was 60-75 micron.
But now that thickness is reduced to
55 micron only. All these developments
have led to cost and resource reduction.”
Advancing step by step With the sole aim of achieving sustainability,
the plastics packaging companies have
adopted various steps for downgauging of
packaging materials. Pandya notes, “We
have taken up the task of optimisation of
film and laminates structures after proper
stability study. We are also using new-
generation polymers and films to provide
higher strength at lower thickness. With
this step, we are able to reduce per pack
weight, thereby leading to less material
usage, less energy consumption and less
cost incurred without compromising on
the basic properties.”
He adds, “In 2010-11, we developed
a new light-weight packaging solution
for a snack food company in India. We
reduced the thickness of the laminate from
66-68 gm/sq m to 52 gm/sq m. This
proved to be a benchmark of our efforts
towards sustainable development. We are
now manufacturing biodegradable and
thin laminates.”
Future trendsWhile considering the sustainability of
packaging, multiple factors must be taken
into account, including the actual energy
costs of production & transportation,
quantity of raw materials used for
manufacturing, toxicity and carbon
emissions in production & decomposition
as well as overall biodegradability of the
finished product. Packaging companies
are working efficiently towards fulfilling
all these parameters, especially for
conserving resources and reducing cost by
material downgauging.
Downgauging has become a
buzzword among material suppliers and
the processing community. It allows
packagers to offer the same products with
higher product-to-package ratios by using
thinner materials. This approach to resin
implementation has changed the way the
industry does business.
Pandya avers, “The future trends
for conserving resources and reducing
cost would include reusable packaging,
elimination of secondary packing by
developing sustainable inner/primary
packaging, innovation in reducing number
of layers in high-barrier laminates, thereby
reducing material consumption, energy
usage and production costs.”
Besides downgauging of packaging
material, various steps could be
taken by the companies for ensuring
sustainability. Pandya avers, “These
steps include replacing old low-
speed high-wastage machinery with
new-generation technology; this can
be done by using alternative films
and granules after studying the
performance criteria of product &
packaging needs for the same; using
high-barrier non-traditional films
with enhanced barrier properties to
replace traditional films as an import
substitute for food, dairy & pharma
sector; optimising process & production
costs; reducing wastage by deploying
advanced technology for production,
focussing on Research and Development
(R&D) and new investments in R&D.
Thus, in future, more efforts will be taken
by companies for ensuring sustainability
in packaging.”
Email: [email protected]
SUSTAINABILIT Y: Reducing Reducing carbon Footpr int
76 Modern Packaging & Design July-August 2012
Rising energy prices and environmental consciousness are driving packaging companies towards sustainability. An efficient way to ensure sustainability is through reducing carbon footprint by recycling. Avani Jain explores the significance of recycling for reducing packaging carbon footprint.
Economic growth and
prosperity are essential
components of sustainable
development. The United
Nations estimates that the population
of the planet will grow to 9.2 billion
by 2050. The efficient and productive
industry engaged in truly sustainable
practices is essential to meet the
incredible increase in demand for goods
and resources that this growth implies.
Historically, increased use of packaging
has accompanied economic growth.
A goal of sustainable packaging is to
facilitate economic growth by delivering
the benefits of packaged goods without
the negative impacts traditionally
associated with packaging and related
processes. Thus, sustainable packaging
transforms the world into a greener and
cleaner place, and safeguards the natural
ecosystem.
Tracking the footprintIn an era of rising energy costs and
scarce resources, companies need to
work towards packaging that not only
adds value to end products, but also
conserves the environment, thus creating
sustainability in packaging. One way
of achieving this goal is reducing the
packaging carbon footprint through
recycling solutions.
Carbon footprint is the overall
amount of greenhouse gas emissions,
consisting primarily of carbon dioxide,
associated with an organisation, event or
production. It is one of the most common
measures of the effect of an individual,
community, industry or country on the
environment. An increase in greenhouse
gas emissions, and therefore in carbon
footprint, is the primary event associated
with climate change that has led to
global warming.
The carbon footprint generated
during packaging can be curbed by
various methods such as downgauging of
packaging materials with improvements
in designs and raw material,
development of fuel efficient machines
& equipment, power generation from
natural resources rather than fossil fuel
and, most importantly, adoption of
efficient recycling technologies.
Cesar Rodriguez, Chief Executive
Officer, MachinePoint Group, asserts,
“Recycling is the key for carbon
reduction, but at the same time, it is
difficult to implement. It should be
done in a correct manner in order to
really achieve a carbon reduction.”
Recycling solutions Recycling reduces carbon emissions by
reducing the need for raw materials,
which generally require more energy
76 Modern Packaging & Design July-August 2012
SUSTAINABILIT Y: Reducing Carbon Footpr int
Reducing Carbon Footpr int
Modern Packaging & Design July-August 2012 77
to produce and transport than recycled
materials. It helps in reducing waste in
landfill and the consequent methane
emissions. Recycling of packaging
waste, both post-consumer and waste
generated in the manufacturing process,
is beneficial. An efficient and real-time
recycling and returnable process should
be implemented to capture & bring back
waste to recyclers/packing companies
for recycling. Recycling uses less energy
and produces less pollution than making
the products from scratch. For example,
making aluminium cans from old ones
uses one-twelfth of the energy than
making them from raw materials.
There are various strategies in
the plastics industry which can be
adopted by the companies for reducing
their carbon footprint through
recycling. Rodriguez notes, “Reducing
packaging wall sizes with multi-layer
products will make them lighter but
stronger, and thus, help reduce carbon
footprint by reducing energy required
for transportation. Another way is to
develop mono-polymer products, where
a bottle, cap and label are made from
the same material. The recycling of this
bottle is easier, as no product separation
will be required as the polymers used
are not different.”
Various machines are available in the
market, which can enable easy recycling
of plastics. “Size reduction machinery
and re-pelletising machinery can help in
reducing carbon footprint because these
machines are mainly used in industrial
recycling. Further, the recycling process
usually consists of the leftovers of the
process to input them back in the
process, making this method of recycling
the most efficient one in terms of carbon
reduction,” suggests Rodriguez.
Challenges posed The market for sustainable development
and awareness about reducing carbon
footprint through recycling is increasing
in India. However, the technology and
machinery needed for recycling are
still not fully developed in India. The
companies operating in the Indian
market have to import machines and
technology from overseas, which makes
sustainable packaging a costly affair.
Thus, the recycling technology solutions
providers have to spread their wings to
help their customers in the best possible
manner. The main challenge lies in
the correct separation of the waste to
be recycled. Rodriguez opines, “For
this reason, industrial recycling where
waste separation has proved to be easier
is economical and environmentally
more interesting than post-consumer
recycling, where the correct separation,
cleaning & sorting of all materials is a
challenge.”
Future trends Adopting more efficient recycling
technologies will result in increased
energy efficiency and economies of
scale. Rodriguez avers, “The new trends
would include the development of mono
products. At the same time, multilayer
products can go for a weight reduction,
as these are more difficult to recycle.
However, the real challenge remains
the development of technologies for
separation process employed during
recycling.”
Green footprintPackaging sustainability will be the
way to the success of a business model
and place industrial development on
the ‘green route’. Cutting back on
amount of waste seems a daunting task,
but applying these practices to one’s
manufacturing processes is the need
of the hour. Thus, it is important for
the industry to learn to adapt to the
packaging 3Rs – reuse, reduce & recycle
– which can help achieve sustainable
packaging through reducing carbon
footprint to a large extent.
Email: [email protected]
Cesar Rodriguez��� ��[�!��]�� ����� MachinePoint Group
Reducing packaging wall sizes with multi-layer products will make them lighter but stronger, and thus, help reduce carbon footprint by reducing energy needed for transportation. Another way is to develop mono-polymer products, where a bottle, cap and label are made from the same material.
SUSTAINABILIT Y: Inter face - Pramthesh Pandya
78 Modern Packaging & Design July-August 2012
“Today, the renewable-recyclable-compostable trend is seen in the industry”
Why is there a need for sustainable packaging in India?With global plastics consumption
expected to reach a mammoth
300 million tonne by 2015, the
global packaging industry is set for
a strong growth in the future. The
Asia-Pacific market will be the key
market driving this growth, with India
and China collectively making a sizeable
contribution. The factors influencing
this growth are development of
new-age plastics, emergence of
new applications and focus on
green chemistry due to legislative
& environmental requirements, all
leading to development of sustainable
packaging in the country.
What are the principles governing sustainable packaging?Sustainable packaging works on four
principles – effective, efficient, cyclic
and clean. Effective means that the
packaging system should add real
value to the society by effectively
containing and protecting
products as they move
through the supply chain
and by supporting
informed &
responsible
consumption. Efficient indicates
that the packaging system should be
designed to use materials and energy
as efficiently as possible throughout the
product life cycle. This includes material
and energy efficiency in interactions
with associated support systems such as
storage, transport and handling. Cyclic
means packaging materials used in the
system should be cycled continuously
through natural or industrial systems,
minimising material degradation. Clean
states that packaging components used
in the system, including materials,
finishes, inks, pigments and other
additives, should not pose any risks to
humans or the ecosystem.
What are the key growth drivers for sustainable packaging industry? The Indian sustainable packaging
category, which is currently recording
annual growth of 25 per cent, was valued
at $ 3.19 billion in 2011. Factors such
as high consumer awareness, increasing
popularity of smart & sustainable
packaging among leading companies
and adoption of environment-friendly
technology in sustainable packaging
production have contributed to the
increase in demand for active, smart &
sustainable packaging. Further, rising
concerns over environmental hazards,
carbon emissions and waste reduction
targets specified by different countries,
are the factors likely to boost the market
for sustainable packaging solutions.
What are the leading innovations making headway in the segment? Some new concepts in sustainable
packaging segment include reduction
in the usage of plastics at source,
biodegradable laminates, paper-based
packaging materials, eco-friendly
flexi-tube for cosmetics & pastes,
slider zipper with diaphragm and non-
plastic laminates for mouth freshener
industry. One of the most visible trends
in sustainable packaging is the focus on
environment-friendly materials. Today,
the renewable-recyclable-compostable
trend is seen in the industry, from
grocery aisles to shoe stores, shipping
containers to the retail shelf.
What steps has your company taken to ensure packaging sustainability? We constantly work to reduce product
waste, waste to landfill and solvent
usage across the manufacturing process;
preventing over-packaging, improving
energy efficiency through various
methods and usage of biodegradable
materials to offer sustainable solutions
to our customers.
Email: [email protected]
…opines Pramthesh Pandya, Head-Unit & Business Development, Parikh Packaging Pvt Ltd. In an interaction with Avani Jain, he discuses the growth and demand of sustainable packaging in India, while outlining the challenges and opportunities facing the segment.
SUSTAINABILIT Y: Roundtable
Modern Packaging & Design July-August 2012 79
Can recycling technology in India achieve competitive results
for the market?
Sunil JainPresident, Rajoo Engineers Ltd
The demand for sustainable packaging is low in India and not many companies are willing to invest in it. Further, technologies are not sufficient to support sustainable packaging initiatives such as recycling. There is lack of investment in developing recycling technologies in India. However, the multinational companies in this segment have begun recycling plastic waste and using recycled plastics for packaging. But these are few is number as against the domestic players in the market. The major reason is that most companies believe that recycled plastics is a low-end product and the manufacturing process is messy. Thus, in order to motivate companies to undertake recycling, it is important to change their perception, upgrade technology and invest in developing recycling technologies, as this will become the future of the plastics and allied packaging industry. Since the demand for plastics is growing, recycling is required to meet the growing demand. Thus, recycling technologies in India can achieve competitive results for the market in future.
In recent years, the demand for sustainable packaging has increased and so has the demand for recycling technologies. Avani Jain speaks to some industry experts to explore whether companies in the country are willing to take up recycling on priority and whether recycling technology can achieve competitive results in future.
Vineet Desai Head-Sales & Marketing,
Unnati Speciality Films
Today, few companies have taken up the task of recycling plastic waste and are using recyclable plastics. The major reason is that recycling plants are expensive and not everyone can afford to buy these lines. Further, in India, the technologies related to recycling are not adequate as compared to other nations. The usage of recycled plastics is also limited here. However, the scenario is changing and companies are considering their own recycling lines for plastic wastes. This is because of the increasing environmental consciousness. Awareness is also spreading about the fact that production of recycled resin uses 90 per cent less energy and emits 78 per cent less greenhouse gases than producing virgin resins. Recycling of plastics saves much more energy compared to burning it in an incinerator. Thus, employing recycling technologies by companies in this segment has several benefits.
Umesh Sharma Managing Director,
Julison Packaging India Pvt Ltd
The market for sustainable packaging has not yet matured in India and only a few companies have taken up to this task. The major reason behind this is lack of technology, infrastructure and funds. These reasons remain the same as only few companies involved in recycling plastic materials. Apart from this, the perception of people is an issue, as people think that recycled material is not a good option. Moreover, plastic materials can be recycled when the volumes are large, but in India, this is not the case. Unlike other countries where the production and consumption is huge and recycling is considered as a feasible option, but this is difficult in India where a large number of small & medium enterprises with lower capacities also operate in this segment. Also, recycling means adopting compatible converting technology, which, at present, is not adequate in India. Thus, recycling technology in India can achieve competitive results for the market, provided there is adequate fund, infrastructure and, above all, willingness of companies to adopt these futuristic trends.
With the general outlook shifting towards sustainable packaging, the demand for recycling technologies will increase in future. Although not many companies are currently willing to invest in recycling, these technologies will certainly define
the future of the surging plastics and the allied packaging industry.
Editorial take:Email: [email protected]
FACILIT Y VISIT: Uf lex Engineer ing Ltd
80 Modern Packaging & Design July-August 2012
Uflex Engineering Ltd is one
of the largest companies
offering flexible packaging
solutions in India with large
manufacturing capacities of plastic film
and packaging products. Headquartered
in Noida, National Capital Region (NCR)
- New Delhi, and listed on Bombay
Stock Exchange and NSE, the company
has a strong manufacturing base in India
( Jammu, Noida and Gwalior), Mexico,
Dubai and Egypt, providing end-to-end
solutions to clients across 100 countries.
It caters to global markets such as USA,
Canada, South America, UK, Europe,
Russia, Commonwealth of Independent
States (CIS) countries, South Africa and
other African countries, the Middle East
and South Asian countries. It also has
offices in the UAE, Europe and North
America, and enjoys a formidable market
presence in over 85 countries.
Manufacturing facilityUflex works with a vision towards creating
total flexible packaging solutions for the
world. Its strategic locations across the
globe have helped the company to cater to
global demands with solutions that keep
its goals in focus. The Uflex facility enjoys
ISO 9001 and ISO 14001 certifications,
besides Food and Drug Administration
(FDA) & German Federal Health Office
(BGA) approvals for its products.
Being a multi-faceted organisation,
Uflex has integrated its operations from
the manufacture of polyester chips,
films [Biaxially Oriented Polyethylene
Terephthalate (BOPET), Biaxially
Oriented Polypropylene (BOPP) and
Cast Polypropylene (CPP)] — both in
plain and metalised form — coated films,
laminates, pouches, holographic films
gravure cylinders, inks and adhesives to all
types of packaging & printing machines.
Uflex is committed to the industry by
providing technical know-how and being
the trendsetter in the flexible packaging
space. Being on the cutting edge of
innovation, it develops advanced products
that cater to the changing demands of the
packaging industry.
Business divisionsUflex is a one-stop shop for flexible
packages. It provides complete integrated
packaging solutions, right from design to
delivery. Catering to the specific needs
of customers for laminates and pouches
by constantly redefining cost-effective
packaging options is its tradition. With
almost two decades of experience
in flexible packaging and significant
investments, Uflex has perfected its
processes and technology to produce
high-quality flexible packaging materials
on time and within budgets.
Sanjay Malik Sabharwal, Vice
President-Marketing, Uflex Engineering
Ltd, says, “Our in-company divisions and
group companies located nearby produce
all critical inputs, such as the BOPET and
BOPP films, inks, adhesives & substrates,
holographic films, metalisation facility,
blown film and other such raw materials.
Through our innovations in packaging,
we enable our customers to resolve various
problems.” Uflex is a pioneer in providing
converting machinery to the packaging
���������]����������[�'��q��{����With a paradigm shift in the food packaging segment, India is moving towards more consumer-friendly flexi-packaging solutions. This has seen Uflex Engineering Ltd emerge as a prominent player in this field globally. Anwesh Koley tracks the journey of the company as it has transformed flexible packaging through its innovative concepts.
Printing machine in action
Uflex Engineer ing Ltd
Modern Packaging & Design July-August 2012 81
industry. Its Converting Division,
engaged in the business of packaging
and converting machines, was established
in Noida in 1984, and it is one of the
best-in-class facilities manufacturing
packaging machinery in India.
Diverse portfolio Boasting of a wide range of machines
for flexible packaging, Uflex has a
solution for every packaging need. From
semi-automatic to high-speed automatic
machines incorporating the latest in
automation technology, the company has
a customer-specific approach through
efficient engineering. There are machines
that provide a wide ambit of tailor-made
packaging printing and allied machinery
as per customer specifications. Uflex has
also introduced the concept of reusable
carry bags with Pilfer-Proof Seal Rope
Handle for packaging rice.
Packaging machines are broadly
classified in three categories: form-
fill, seal-wrapping and special-purpose
machines. Vertical and high-speed
horizontal form-fill-seal machines are
single- and multi-track machines to pack
granules, powders and liquids. Wrapping
machines such as flow wrap, over wrap
and candy wrap machines are used to
pack solid products such as candy, biscuits
and electrical switches. Semi-automatic
machines such as vacuum nitrogen
flushing and sealing machines are used
for flexomatic for packaging liquids &
band sealers.
Printing and allied machines include
both Electronic Line Shaft (ELS)
drive and Mechanical Line Shaft drive
(MLS) drive lamination machines
(dry and solvent-less lamination),
inspection, slitting & doctoring machines
as well as pouch making machines.
Research and Development (R&D)The company’s R&D sets standards
for quality machines globally. The
company boasts of several facilities with
sophisticated equipment to meet customer
demands. The company believes that
launching new and upgraded concepts
with a single-minded commitment to
quality is the key to success. The access to
a large pool of engineering skills, in-depth
and product understanding is the secret
to the company’s constant stream of
innovative concepts.
Management strategiesUflex has been receiving the constant
support of its customers by extending
quality services. The company has
been following different management
strategies to become the leader in the
current competitive packaging scenario.
“Uflex has joined forces with customers
to achieve European quality at Indian
prices. With the world getting smaller
through the rapid spread of knowledge
and technology, it is important to
understand the customers’ needs and work
accordingly,” adds Sabharwal.
Innovative marketing for the futureIn the relentless pursuit of its vision, the
Uflex Group strives to offer total packaging
solutions to its customers. This includes
thorough understanding of customer
requirements, in-house development of
solutions and offering the customer a cost-
effective packaging solution. Sabharwal
opines, “We believe that before and
after-sales service is a major determining
factor for success or failure. Repeat orders
can come only from satisfied customers.
We recommend the correct method and
machinery to all our customers. Although
Uflex specialises in the manufacture of a
wide variety of packaging and converting
machines, the crux of its expertise lies in
its ability to respond to customer-specific
requirements. At Uflex, we follow a process
of constant innovation to match customers’
specifications.” Photo: Amit Kumar
Email: [email protected]
Sanjay Malik SabharwalVice President-Marketing
���� �������������������in the manufacture of a wide variety of packaging and converting machines, the crux of its expertise lies in its ability to respond � ���� ������������requirements.
Pouch making machineAssembly hall area
INSIGHT & OUTLOOK: Consumer- f r iendly packaging
82 Modern Packaging & Design July-August 2012
P V Narayanan
P ackaging has become a
revolution today, bringing in
fundamental changes, massive
expansion and exponential
developments. The context is indeed
social, economical and technological
changes. The changing trends, consumer
preferences and causes are built around
convenience features, quality & quantity
assurance, preference to branded
products, product & use information,
price stability, value addition and dosage
factors. The responsibility of packaging
slowly moves from a utilitarian to
promotional and communicative
and from service oriented to symbol
oriented. Packaging that encompasses
various inter-related functions has also
moved to be more expressive from
the traditional functional aspects.
Consumerism has thus become the
watchword for package designers
and marketers, as today they have to
address the consumer eating habits,
fast diminishing family sizes, average
consumer pattern becoming mosaic,
monolithic functionalism shifting to
hedonism, variations in consumer goods
and shifts in distribution & marketing
changes.
Understanding consumerism The social and societal changes
underline and differentiate more
than just consumer-friendliness. It
is not mere convenience but includes
significant additional responsibility.
What a consumer-convenient pack
should also address is satisfactory health
and hygiene, besides pilfer-evidence, as
well as tamper identification to ensure
that the consumer gets the right product.
The consumer demographic groups
are of kinds – ‘what a child cannot
access’ and ‘what an elderly can access
more easily’.
The urban consumer is fundamentally
different from the conservative budget
shopper of earlier decades. This is
augmented equally by the increasing
exposure to western lifestyles and habits.
The responsibility of packaging today has moved on from being service-oriented to promotional and a means of communication with the customer. The best way to differentiate one’s products on the market shelves is value addition, and thereby paving the way for consumer-friendly packaging.
Enhancingcustomers’experience
Consumer- f r iendly packaging
Modern Packaging & Design July-August 2012 83
The consumer demographics is evolving
in smaller towns and rural areas where
a shift in shopping patterns & buying
habits is motivated by consumers’
desire to emulate urban lifestyle.
Consumers and technologies will drive
the inventions and innovations. It is
no more generalistic, but scientific,
with the world becoming increasingly
uncertain with respect to brands
with consumer thrusts. Consumer
expositions with increasing literacy
will demand novel concepts. Consumer
expectations will undergo a sea change.
They will continue to be cost centric,
but value-for-money propositions
to higher value offerings will surface
strongly. Packaging will become the
vital opportunity to build new brands,
reinforce and add value even for an
existing brand. The package becomes
the resource for the entire marketing
chain and interacts directly with brand
and the consumer. Thus, markets and
consumers will be the drivers for new
products, convenience factor, brands and
supply chain activities.
Packaging convenience Consumers of today look for a package
that is easy to handle, portable, easy to
open and reseal and also satisfy other
demands & needs. Typical user-friendly
packages identified by a consumer
survey include:
Packaging of liquid soap and ready-
to-use packs
Packs with top-slide zippers as the
most desirable closures
Ease of use of plastic jars
Following are typical packages that are
uncomfortable to handle:
Packaging and labels that are
difficult to read or understand
Finding contents spoiled after
opening a package
Spilling on first pour
Roll-on Pilfer Proof Caps (ROPP)
caps continue to rotate instead of
breakage of the steps
A well-defined consumer-f riendly
package should address the target
audience, consumer insights and
consumer convenience. Understanding of
the target audience for the product plays
a crucial role in developing the pack.
The needs of the consumers vary within
the groups. Packaging of toys should be
more appealing to the children’s category
than any other consumers. Consumer
insights when taken into account at
an early stage of package development
can help in the right innovation and
design. One can explore the ideas by the
consumers. These ideas can relate to the
shape, colours, typography, feel, touch
and texture of the package.
A survey into the feel of the
consumers will open up new doors for
product and package developments
in terms of requirements of the user.
Considering these requirements will
help in designing a package that can
meet the convenience factors of the
end user. The task of understanding the
consumer is a joint research between
the marketing, manufacturing, purchase
and supply chain teams. Understanding
the consumers also revolves around
questions such as – ‘who are they?’
‘what are their needs?’ ‘what are their
practices?’ and ‘what are their habits?’
Also, understanding the consumers with
respect to other aspects should analyse
use and consumption pattern as well as
consumption & use frequency.
The demand for consumer-friendly
packaging is essentially the market
driver enabling introduction of product
categories and adoption of different
technologies. The strategy is indeed
based on a global scope catalysed by
leadership and specialisation. The
major business segments and, indeed,
consumer goods & food services,
personal care, healthcare and pharma
products, open up opportunities for a
wide range of package types, eg, shapes,
sizes, technologies and many to suit
specific customer groups and varying
end-use applications. Reversing loop
innovations could succeed, as consumers
today are willing to experiment, adopt
new products and experiences. This can
also become more successful if the ‘new’
can articulate aspirational needs and
seek solutions, with affordable price,
better quality and high reliability being
the new buzzwords.
Consumer-friendly packaging offers
a curiosity factor, value addition and
opportunity exploration. Innumerable
examples can be cited for such a
packaging – press-in pill dispensers, caps
for controlled dosage, spouted pouches,
wine pouches with tap, single-serve tea
pouches, stand-up pouch with screw-on
spoon, twin-compartment pack, cartons
with tear-off ribbons, three/two-in-one
coffee/tea pouches, etc.
Infusing value to the packToday, every company is willing to
differentiate their products f rom
others in the point-of-purchase shelf.
A value-added pack is the best way to
differentiate the product on the shelf.
The concept of value addition in the
pack is different from manufacturer to
manufacturer. For some, the concept of
value-added pack may mean providing
an offer pack, while for some it may be
providing the pack with a reusability
feature and, for yet others, it may be
through inbuilt consumer-friendly user
features & security measures.
The development of consumer-
f riendly packaging is important
since everyone wants to offer some
or other advantages to consumers
through their product-package
combination or in isolation of either.
However, the path to consumer-
f riendliness is indeed challenging
as many different parameters must
be considered individually and
collectively.
P V Narayanan is a
Member of Board in
APEDA (Ministry of
Commerce). He is also
Secretary General -
IPMMI and Chief Executive - PFFCA.
He is a recognised UNIDO, ITC and
CFTC (UK) expert consultant in
the field of packaging.
Email: [email protected]
PROJECTS
84 Modern Packaging & Design July-August 2012
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers such as consultants, raw material suppliers, plant & equipment manufacturers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the packaging, printing and converting industries.
Battery manufacturing and packaging facilityProcter & Gamble Duracell
Project typeExpansion
Project newsDuracell is making a $36 million
investment to expand its Cleveland,
Tennessee facility. P&G Duracell, the
manufacturer of high-performance
alkaline batteries, will expand its capacity
and create about 60 jobs, thereby
bringing its workforce to more than 500
personnel.
Project locationUnited States
Project cost$ 36 millionImplementation stageOngoing
Contact details:
Procter & Gambles Duracell
Berkshire Corporate Park
Bethel, Connecticut- T 06801
United States
Tel: +1800-551-2355
Email: [email protected]
Integrated textile park The North India Printers Association
(NIPA)
Project typeNew facility
Project newsProposed integrated Green Field
Textile Park is being set up as part of
the association’s efforts to focus mainly
on the US market. This textile park,
claimed to be the country’s first privately-
held textile park, would have weaving,
processing, spinning, stitching, packaging
and dispatching facilities at one location.
Project locationIndia
Project cost` 2000 million
Implementation stageImplementation stage
Contact details:
The North India Printers Association
C/o. Preeti Art
A-55, Royal Indl. Estate
Naigaum Cross Road
Wadala, Mumbai, Maharashtra
Tel: 0161-2404221, 2404093
Fax: 0161-2406434
Email: [email protected]
Packaging machinery and technologyPaharpur Industries Ltd
Project typeNew facility
Project newsPaharpur Industries Ltd (PIL), a wholly
owned subsidiary of Paharpur Cooling
Towers Ltd and manufacturers of a wide
range of packaging products, will invest
around $ 22.5 million over the next five years
in acquiring new machinery and technology.
The company is working on a five year
rolling plan to invest around ` 80-100 crore
to acquire new technologies and machinery
starting with a coater laminator that would
cost around $ 4.5 million
Project locationIndia
Project cost$ 22.5 millionImplementation stageImplementation stage
Contact details:
Paharpur Industries Ltd
2-A, Paharpur Business Centre
21 Nehru Place Greens
New Delhi
Tel: 011-6207727 / 28
Fax: 011-6452736
Email: [email protected]
Printing institute cum testing laboratory projectThe North India Printers Association
(NIPA)
Project typeNew facility
Project newsGlasgow Metropolitan College (GMC)
and NIPA have signed an agreement
under which GMC will provide syllabus
and other technical know -how to the
students. The need for such an institute
has emerged with the changing technology
and installation of sophisticated
computerised machines, which has made
it necessary to up-scale the printing and
packaging industry in India.
Project locationIndia
Project costNot known
Implementation stagePlanning
Contact details:
The North India Printers Association
C/o. Preeti Art
A-55, Royal Industrial Estate, Naigaum
Cross Road, Wadala, Mumbai, Maharashtra
Tel: 0161-2404221, 2404093
Fax: 0161-2406434
Email: [email protected]
Information courtesy: Tendersinfo.com
1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India
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Latest Popular Tenders brought to you by www.tendersinfo.com
TENDERS
Modern Packaging & Design July-August 2012 85
Bottling line for hot fruit juicesOrg : The Maharashtra Agro-Industries Development Corporation LtdTRN : 11528580Desc : Consultant for setting up bottling line for aseptically packaging hot fruit juicesBOD : 10 July, 2012LOC : IndiaBT : Domestic competitive bidding
Packaging of lubricants in HDPE containersOrg : Indian Oil Corporation Ltd (IOCL)TRN : 11509036Desc : Packaging of lubricants in HDPE containers.BOD : 12 July, 2012LOC : IndiaBT : Domestic competitive bidding
Packaging of lubricants in small pack containersOrg : Indian Oil Corporation Ltd (IOCL)TRN : 11509093Desc : Packaging of lubricants in smaller size HDPE containers.BOD : 13 July, 2012LOC : IndiaBT : Domestic competitive bidding
Filling and corking of drugs Org : Borisovskiy Zavod Meditsinskikh PreparatovTRN : 11569178Desc : Supply of line for filling and corking of liquid drugs in 30/50/100 ml bottles with cleaning station and tunnel for drying bottlesBOD : 16 July, 2012LOC : BelarusBT : International competitive bidding
Pharma packaging Org : Ministry of HealthTRN : 11545580Desc : Supply of liquid filling machine with accessories for pharmaceutical services department at Al Sabah HospitalBOD : 16 July, 2012LOC : KuwaitBT : International competitive bidding
Automatic shrink packaging machineOrg : Indian Railway Catering and Tourism Corporation Ltd (IRCTC)TRN : 11499075Desc : Automatic shrink packaging machineBOD : 20 July, 2012LOC : IndiaBT : Domestic competitive bidding
Automatic wrap around labeling and rinsing Org : Indian Railway Catering and Tourism Corporation Ltd (IRCTC)TRN : 11499074Desc : Automatic wrap around labeling and rinsing with filling and capping machine BOD : 20 July, 2012LOC : IndiaBT : Domestic competitive bidding
Packaging line for 500 ml PDW bottle Org : Indian Railway Catering and Tourism Corporation Ltd (IRCTC)TRN : 11498608Desc : Packaging line for 500 ml PDW bottle BOD : 20 July, 2012LOC : IndiaBT : Domestic competitive bidding
Procurement of conveyor roller spares Org : Western Coalfields Ltd TRN : 11468354Desc : Procurement of conveyor roller spares BOD : 20 July, 2012LOC : IndiaBT : Domestic competitive bidding
Supply of conveyor belt Org : Northern Railway (NR)TRN : 1518096Desc : Supply of conveyor beltBOD : 20 July, 2012LOC : IndiaBT : Domestic competitive bidding
Latest Popular Tenders brought to you by www.tendersinfo.com
Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.
Information courtesy: Tendersinfo.com
1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India
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EVENT LIST
86 Modern Packaging & Design July-August 2012
PackPlus South 2012This will be an opportunity to
focus on the emerging opportunities in
the fast industrialising markets of South
India. The packaging sector of this region
will be represented through its latest trends
and technologies, especially by SMEs;
July 6-9, 2012; at Hyderabad International
Trade Exposition Centre (HITEX),
Hyderabad
For details contact:
Print-Packaging.Com Pvt Ltd
F101, 1st Floor, Tower 7, International
Infotech Park, Above Vashi Railway Station
Vashi, Navi Mumbai - 400705
Tel: 022-27812093/2619/2657
Fax: 022-27812578
Email: [email protected]
Website: www.packplussouth.in
Compack 2012This is among the leading trade exhibition
for the entire packaging process such
as bagging, sealing, strapping, filling,
conveying, dosing, etc. Compack 2012
will provide the Indian packaging
industry with an excellent opportunity for
all industry players to meet on a common
platform; July 13-15, 2012; at Chennai
Trade Centre, Nandambakkam, Chennai
For details contact:
Narendar Bafna
Smart Expos
New No 116, Mount Road
Guindy, Chennai - 600 032
Tel: 044-22501986/1987
Mob: 09952966752
Email: [email protected]
Website: www.compackexpo.com
Print & Packtech 2012This exhibition will reflect the market’s
evolutionary with special focus on the
integration of printing and packaging
processes and its supply chain. This event
will enable both industries to claim market
leadership and future opportunities;
August 24-27, 2012; at Palace Grounds,
Bengaluru
For details contact:
Cyril Pereira
25, 3rd Floor, 8th Main Road
Vasanthnagar, Bengaluru - 560 052
Tel: 080-4330402, Mob: 09886789641
Fax: 080-22352772
Email: [email protected]
Website: www.printandpacktech.com
PackPlus 2012In order to showcase the opportunities
and growth potential within the Indian
packaging industry, PackPlus 2012 will
provide a global platform to the leaders
of this industry, who will present some of
the latest innovations and developments
from macros the world. Strong growth in
sectors like fast moving consumer goods,
pharmaceuticals, liquor, and cosmetics has
had a positive rub off on the packaging
industry.; December 7-10, 2012; at India
Expo Centre, Greater Noida, Delhi NCR
For details contact:
Print-Packaging.Com Pvt Ltd
F101, 1st Floor, Tower 7, International
Infotech Park, Above Vashi Railway Station
Vashi, Navi Mumbai - 400705
Tel: 022-27812093/2619/2657
Fax: 022-27812578
Email: [email protected]
Website: www.packplussouth.in
Printpack India 2013This edition will focus on disseminating
information on technology, market
perspectives and various developments
taking place around the world, relevant to
the Indian printing, packaging, converting
and allied machinery manufacturing
industries; February 23 to 28, 2013; at
India Expo Center & Mart, Greater
Noida, Delhi NCR
For details contact:
Indian Printing Packaging and Allied
Machinery Manufacturers’ Association
(IPAMA)
Plot No C - 54
Sector-62, Institutional Area,
Noida - 201 307, UP
Tel: 0120-4292274/75, 2400110
Fax: 0120-2400109
Mob: 9717199385
Email: [email protected], [email protected]
Website: www.ipama.org
National
India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.
For details contact:Infomedia 18 Ltd,
Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. ��=�;##�>;;>�\<Q3���Z�[=�;##�>;;>�\\??��������=��[q�^� �����3X_����`'=�+++_��"[q�_���
ChennaiTamil Nadu
Nov 22-25, 2012
LudhianaPunjab
Dec 21-24, 2012
PuneMaharastra
Nov 2-5, 2012
AhmedabadGujarat
Oct 5-8, 2012
IndoreMadhya PradeshJan 11-14, 2013
�!���q!�Uttarakhand
Feb 23-26, 2013
AurangabadMaharastra
Feb 1-4, 2013
EVENT LIST
Modern Packaging & Design July-August 2012 87
PPMA Show 2012 This is among the leading trade shows
endorsed by PPMA. It offers enormous
opportunities to engage with manufacturers,
processors and engineers looking to source
processing & packaging machinery &
equipment to enhance their operational
productivity; September 25-27, 2012; at
National Exhibition Centre, Birmingham, UK
For details contact:
Graham Earl
Exhibition Manager
Reed Exhibitions Ltd
Gateway House, 28-The Quadrant
Richmond, Surrey, TW9 1DN, UK
Tel: +44 (0)20-89107890
Fax: +44 (0)20-89107877
Email: [email protected]
Website: www.ppmashow.co.uk
Paper Arabia 2012 This event will feature a broad range of
industry verticals within paper packaging,
such as tissue manufacturing, paper
converting machinery and chemicals,
processing & recycling solutions. It is the
right platform to reach out to decision-
makers, traders, printers and packaging
designers in the Middle East; October 1-3,
2012; at Dubai International Convention
& Exhibition Centre, UAE
For details contact:
Rajesh Nair
Exhibition Manager
Al Fajer Information & Services
PO Box: 11183, Dubai, UAE
Tel: +971-4-3406888, Fax: +971-4-3403608
Email: [email protected]
Website: www.paperarabia.com
Tokyo Pack 2012 This is among the largest international
packaging shows in Asia. It provides
strong support for expansion of business
opportunities owing to emphasis on
innovative product design and packaging;
October 2-5, 2012; Tokyo International
Exhibition Center, Tokyo, Japan
For details contact:
Japan Packaging Institute
10F Togeki, Bldg 4-1-1
Tsukiji, Chuo-ku, Tokyo - 104 0045, Japan
Tel: +81-3-35431189, Fax: +81-3-35438970
Email: [email protected]
Website: www.tokyo-pack.jp
Packaging Innovations 2012 This conference is for packaging designers
and brand owners to ideate on convenient
& sustainable solutions. From the latest
materials to create customer recognition,
design agencies to create a brand
representing the product, to mock-up
agencies producing the newest concepts:
for producing branded packaging is
represented here; October 4-5, 2012; at
Business Design Centre, London, UK
For details contact:
Adrian Harrow
easyFairs UK Ltd
8 Oak Lane, Twickenham TW1 3PA
United Kingdom
Tel: +44 (0)20-88438800
Fax: +44 (0)20-88921929
Email: [email protected]
Website: www.easyfairs.com
PACKEX 2012 Among the leading packaging trade
shows in North America dedicated to
innovations in processing and converting,
this event will offer hands-on access to the
latest in flexible packaging, cartons, labels
and tags, custom automation equipment,
contract services, printing, converting,
processing, materials, material handling,
software, etc; November 14-15, 2012; at
Montreal, Canada
For details contact:
Jim Beretta
UBM Canon
11444 W. Olympic Boulevard
Los Angeles, CA 90064-1549 USA
Tel: +310-445-4200, Fax: +310-996-9499
Email: [email protected]
Website: www.canontradeshows.com
EMBALLAGE 2012 This is an interactive platform
focussing on new packing design,
exclusive conferences on food safety,
eco-design, recycling, sustainability,
etc. This event will offer exhibitors
and visitors an opportunity to learn
about the packaging industry’s current
development techniques, new strategic
stakes & marketing management policies;
November 19-22, 2012; at Paris Nord
Villepinte Exhibition Centre, France
For details contact:
Flora Liegey
Marketing Manager
Comexposium
70 avenue du Général de Gaulle
F - 92058 Paris-La Défense Cedex
Tel: +33 (0)1-76771424
Fax: +33 (0)1-53309521
Email: [email protected]
Website: www.emballageweb.com
ALLPACK Indonesia 2012 This international packaging exhibition
will feature the latest technology,
machinery, materials system and supplies
for the food & beverage industry, pharma
& cosmetic packaging, bottling, canning
& refrigeration solutions, automation &
material handling, quality control and
testing systems; November 21-24, 2012;
at Jakarta International Expo, Kemayoran,
Indonesia
For details contact:
Krista Exhibitions
Blandogan Street
No 28 D/G - Jakarta 11220
Tel: +62-21-6345861/62
Fax: +62-21-6340140
Email: [email protected]
Website: www.allpack-indonesia.com
International
The information published in this section is as per the details
furnished by the respective organiser. In any case, it does not
represent the views of
EVENT PREVIEW: PackPlus South 2012
88 Modern Packaging & Design July-August 2012
Lionel Alva
Considered as the beginning
of a new epoch for the
packaging industry, 2012
is undoubtedly a landmark
year bringing in new prospects
and possibilities. Industry growth
projections have been extremely positive
with estimates depicting a remarkable
growth rate of 14-15 per cent in the
coming years. The market driver for the
rapid rise of the packaging industry is
the retail boom, with market statistics
registering record growth rates for the
retail sector.
PackPlus South, to be held on
July 6, 2012, at HITEX, Hyderabad,
promises to showcase some of the
industry’s biggest and brightest names,
and give a birds’ eye view of the potential
of the Indian packaging industry.
A global platformWith a strong and consolidated growth
across segments, unprecedented business
opportunities lie ahead for the packaging
industry. Growth in consumer goods and
organised retail mainly drives demand for
packaging. For an investor, the packaging
sector offers promising growth and high
returns. PackPlus South aims to provide
a global platform to the leaders from
this promising industry who will display
some of the latest innovations and
developments from the industry. The
exhibition is expected to set the bar even
higher than the remarkable edition of
the previous year.
“With the third edition of the
PackPlus being organised in Hyderabad,
the foothold has strengthened further.
We have surpassed the last year’s records,
with 250 exhibitors signed up for the
show, and there are two more months to
go. The show will outshine all previous
records to create new landmarks,” avers
Neetu Arora, Director, Print-Packaging.
Com (P) Ltd, the organisers of the show.
Some of the prominent participants
at the event include Hilda Automation
Ltd, KP Tech, Saurabh Flexipack
Systems (P) Ltd, Superpack Packaging
Machines (P) Ltd, Reynders Label
Printing India (P) Ltd, Cyklop
Packaging Systems India (P) Ltd,
Bhavmark Systems (P) Ltd, AKR
Plastic Industry, Hassia Packaging
(P) Ltd, Ecobliss India (P) Ltd, AVP
Papers, Maharshi Udyog, Markem-
Imaje India (P) Ltd, Electronics
Devices, Inpack Fabrications (P) Ltd,
Jay Instruments & Systems Pvt Ltd, SV
Modular Conveyors (P) Ltd, Uflex Ltd
and Interlabels Industries (P) Ltd.
A decade of evolutionThe packaging industry has always
adopted a degree of sophistication in
terms of underlying complex dynamics
of manufacturing since it is a largely
innovation-driven industry. The science
of packaging has evolved rapidly.
This edition of PackPlus South 2012
promises to showcase the latest trends
in technology, especially in CAD/
CAM software and non-woven fabrics,
thus earmarking trends that provide
a panoramic view of the enormous
possibilities in this sector.
Along with the huge value addition
and employment involved in these
activities, packaging has served the
Indian economy by preserving quality
and prolonging the shelf-life of
products such as milk & biscuits, drugs
& medicines, processed and semi-
processed foods, fruits & vegetables,
edible oils and electronic goods,
besides domestic appliances, industrial
machinery and other hardware that
require transportation.
Email: [email protected]
Emphasising on India’s packaging prowessIndia’s packaging industry is estimated to be a ` 8,000-crore industry and is growing at a brisk pace. With an aim to capitalise on this potential, PackPlus South 2012 promises to bring myriad innovations from the packaging industry under one roof, while pushing business opportunities to create further new avenues and possibilities.
BOOK REVIEW
90 Modern Packaging & Design July-August 2012
Most of those outside the field of packaging pay little attention to packaging; although without it the food and other commodities would be unsafe, untransportable and often unusable. This is a good book on plastics packaging, which includes properties, processing, applications and regulations. The authors stress on the relationship between chemical structure and properties of packaging materials. The book is well structured into 16 main chapters, which begin with basic concepts and definitions, polymer structures and properties, major plastics in packaging, additives & compounding. It continues into processes such as adhesion and heat sealing, extrusion, converting, lamination, casting, flexible packaging, thermoforming, injection moulding, blow moulding and bottles. It covers foams, cushioning and distribution packaging as well as mass transfer-related systems & considerations.
The language is lucid, with clear and relevant illustrations. It is a good read for students and teachers of Packaging Technology and Plastics Engineering. However, the book has a chapter on Regulations and Environmental Considerations that deals with the subject in the US, and this is irrelevant for other countries. Thus, as a core book on the subject, it is a must for the library in institutions and will provide immense benefits to students.
Plastics PackagingAuthors : Susan E M Selke, John D Cutter and Ruben J HernandezPrice : ` 6,473
This book explores the interconnected, globally integrated nature of the food packaging industry. It draws on nearly every aspect of science, technology, business, social science and engineering. Rather than present a traditionally linear view of these topics, the author takes a ‘Packaging Cycle’ approach by guiding readers through the life of the package, from raw materials and conversion, operations, distribution, retail, all the way to recycling or disposal by the consumer. The book consists of 12 chapters covering the evolutions and future developments in food packaging technology and is intended for readers with varying levels of experience, Food and Package Engineering provides multi-level accessibility to each topic, allowing both students and professionals to find useful information and develop technical expertise. Rather than being a simple exposition of technical knowledge, the book provides real-world examples as well as challenging problems that require consideration at different levels.
The subject is dealt well, but in many places, a more detailed explanation could have been given. The coverage is wide, but lacks depth in certain topics. Although it does not qualify as a core book, it is useful for additional reference. This is a valuable book for packaging and food engineering institutions and will serve as a good reference to teachers and students alike.
Reviewer: Prof C S Purushothaman, Chair Professor Director, SIES School of Packaging Mumbai.
Food and Package EngineeringAuthor : Scott A MorrisPrice : ` 10,919
Avaliable at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai 400 053��=�;##"#<F>�Q#<;|<<?F�;Q;F����� �[=�;##"#<F>�Q\#\|Q#<;��������=�������'��{�^�����_���
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PRODUCTS
Modern Packaging & Design July-August 2012 93
Looking For A Specific Product?Searching and sourcing products were never so easy.
Just type MPD (space) Product Name and send it to 51818eg. MPD Wrapper and send it to 51818
Invospeed
It is a continuous operating high-speed shrink wrapper with
single- or twin-lane tray packer module. It has an all servo-
driven machine capable for speeds up to 100 cycles/min. It is
available in various configurations (Film only, Pad+Film or Tray
+Film). The machine can handle different types of containers, eg,
bottles, cans, cups, jars, cartons etc. The solid construction, the
almost wear-and-tear free and easily accessible design, ensures a
low maintenance cost. Invospeed requires no change parts when
moving from one size to another.
Clearpack India Pvt Ltd
Mumbai - Maharashtra
Tel: 022-28596422
Email: [email protected]
Website: www.clearpack.com
Co-extrusion blow moulding machinesCo-extrusion blow
moulding machines
have co-extrusion die
heads to combine up to
six different materials,
incorporating high-
efficient melting screws,
linear function for swift
& steady production.
The die-head ensures quality-melted material of non-scorch. Blow
pin units and deflashing units have innovative designs for perfect
neck and bottom deflashing.
Full Shine Plastic Machinery Co Ltd
Tainan County - Taiwan
Tel: +886-4-22765071
Email: [email protected]
Website: www.full-shine.com
Sleeve wrapping machineLantech revolutionary SW series
high-speed sleeve wrapping
machine eliminates many of
the common shrink wrapping
problems that result in poor
package quality. The machine
significantly improves productivity
levels by reducing rework as a
result of poor package quality and reduces downtime due to time
consuming changeovers. The SW series is available in SW-1000,
SW-2000, SW-3000 and SW-5000 models. Features include simple,
intuitive mechanical adjustments that make it easy for operators to
set up systems, extra large operating sweet spot for time, speed and
temperature control significantly improves quality, etc.
Durapak
Chennai - Tamil Nadu
Tel: 044-43033533
Mob: 09840050066
Email: [email protected]
Website: www.durapak.co.in
Automatic extrusion blow moulding machineThis machine is used
for making view stripe/
window line for lubricant
field. The blow moulding
machine is incorporated
with a view of stripe
extruder to produce
various bottles and
containers with the
window line. Carriage movement is under the linear movement with
German parts to provide swift performance, adopting a special brake
system to ensure swift and stable movement of the mould carriage.
Mould clamping is improved in design with column bars for strong
and equal clamping performance.
Full Shine Plastic Machinery Co Ltd
Tainan County - Taiwan
Tel: +886-4-22765071
Email: [email protected]
Website: www.full-shine.com
PRODUCTS
94 Modern Packaging & Design July-August 2012
Thermoform-fill-seal machineThe Veripack Rollstock thermoform-
fill-seal machine is designed keeping
the end customer in mind. This
machines is well ahead in terms of
flexibility, robust construction and
high-end electronics. All models can
handle flexi and rigid packaging films and carry out special skin-type
pack formats; also, changeover from one format to another is simple
and fast.
Veripack Solutions India Pvt Ltd
Mumbai - Maharashtra
Tel: 022-66971133
Mob: 9967752336
Email: [email protected]
Website: www.veripackindia.com
Thermoforming mouldsHigh output is achieved by
maximum cool capacity in
combination with the right form
air technology. The mould is
constructed with a tool layout
for minimum scrap. Optimal material distribution helps save material
by downgauging.
Elpie Engineers Pvt Ltd
Rajkot - Gujarat
Tel: 0282-294522,
Mob: 09712973716
Email: [email protected]
Vacuum packaging machineThe mini counter-top vacuum
packaging machine has standard
features such as high-quality see-
through lid and all stainless steel
body. This machine size overview is
chamber 325 x 300 x 80 mm. seal
beam 300 x 3 x 1 mm, and overall
size of 670 x 385 x 370 mm, hot air
chamber size at 325 x 300 x 80 mm,
seal bar of length 300 and width 3
mm; number of seal bars and chambers: one, power grid voltage:
single-phase 220 V, pressure: 2-5 mbar, pump speed: 4 m3/hr, vacuum
pump power 0.4 hp single phase, etc.
Saurabh Engineers
Ahmedabad - Gujarat
Tel: 079-22911288, Mob: 09824040137
Email: [email protected]
Website: www.indvacindia.com
PRODUCTS
Modern Packaging & Design July-August 2012 95
Case erector Model 330 is a heavy-duty
case erector built for high
continuous production. It is
designed for simple control,
top flexibility and minimal
maintenance. Its continuous motion drive performs case forming and
case sealing operations at speeds of 35 cpm. Using electronics to control
the operations and document their performance on the machine, it is
also operator-friendly with touchscreen controls. Its features include
soft stop, self-lubricating air cylinders, safety guarding, standard fault
detection features and extended blank magazine.
Clearpack India Pvt Ltd
Mumbai - Maharashtra
Tel: 022-28596422
Email: [email protected]
Website: www.clearpack.com
Textile packaging boxesTo ensure scratch-free and
safe handling of sensitive
articles, Nilkamal offers textile
partitioned boxes. These boxes
are useful in automotive industry for transportation and handling of
sensitive components like lamp assemblies, fenders, etc. Being a licensee
of Conteyor NV, Belgium, for their world-class Fitbox Technology,
Nilkamal textile packaging provides an edge over others and is a cost-
effective solution for all industrial needs.
Nilkamal Crates & Bins
Mumbai - Maharashtra
Tel: 022-26818628, 26818888
Mob: 8980011640
Email: [email protected]
Website: www.nilkamal.com
Vertical form/fill/seal machineThis PK 70 Storm vertical form/fill/seal machine
has output of 80-120 pouches/minute, dimensions
is 1,893 mm (L) x 1,222 mm (W) x 1,820 mm
(H), power is 8 kW and the packaging material
is polyester and metalised polyester films. It has
an optional attachment such as multi-head scale,
auger filler, volumetric cup filler, nitrogen gas
flushing system, nitrogen gas flushing system and poking device.
Pakona Engineers (India) Pvt Ltd
Mumbai - Maharashtra
Tel: 022-22854138
Email: [email protected]
Website: www.pakona.com
PRODUCTS
96 Modern Packaging & Design July-August 2012
Linear weigh fillersRequired accessories are double-stage
reciprocating-type air compressor, three-
phase 15-kVA servo stabiliser and Z-type
bucket elevator. Optional systems can be
batch coding device, nitrogen flushing
system, static charge eliminator and extra
collars and trays. The machine can fill and
pack products like rice, pulses, sugar, whole
spices, seeds, grains, etc as well as non-
free-flowing & irregular shaped products.
Inpack Fabrications Pvt Ltd
Hyderabad - Andhra Pradesh
Tel: 040-2724 3869
Email: [email protected]
Flushing and sealing machineNozzle Type Flushing and Sealing Machine
is ideal for 'Pillow Packing' of fragile food
products like potato wafers, banana wafers,
certain fine noodles, etc, to maintain aroma,
freshness, crispness for long time and protect
fragile products from breakage/damage. It is
easy to operate with food switch, has fully
automatic sequence of operation & low cycle
time. The standard seal length offered is 350
mm and width 12 mm (serrated).
Saurabh Engineers
Ahmedabad - Gujarat
Tel: 079-22911288
Mob: 09824040137
Email: [email protected]
Website: www.indvacindia.com
Induction cap sealerWater-cooled Fluxosealer AFX3000
is a heavy-duty induction cap sealer
for high-speed sealing and special
applications. Bottles with neck diameters
ranging from 10-150 mm can be sealed
with ease. Standard features include no
foil detection system, which consists of
sensors to detect induction seal inside
the cap, easy line relocation and plug
& play system. The enclosure is made of MS powder coated/SS304.
Arshad Electronics Pvt Ltd
Mumbai - Maharashtra
Tel: 022-24451709
Email: [email protected]
Website: www.arshadelectronics.in
PRODUCTS
Modern Packaging & Design July-August 2012 97
Blow moulding machine The complete XBLOW X07 series with
platen widths of 350-700 mm is offered.
The new single- and double-station
machine is available with all-electric
(EBLOW) and hydraulic (HYBLOW)
drives. No modifications are required
to use existing Bekum customer blow moulds on these machines.
Continuity of the machine operation, apart from certain extended
capabilities is considered. The machine platens are designed for good
accessibility and ease of maintenance.
Bekum Maschinenfabriken GmbH
Berlin - Germany
Tel: +49-30-74900
Email: [email protected]
Website: www.bekum.de
Labeling machine The automatic BOPP Labeling machine
has fully automatic linear operation
for 200-2,000 ml bottles. Maximum
production speed of 60/90/120/200
bottles/minute. The machine is
built fully in stainless steel. Height
adjustments can be made to suit various
bottle sizes. It requires no cleaning of the nozzle or glue unit, before
production (less maintenance & saves time) and is fitted with PLC.
Hilda Automation
Navi Mumbai - Maharashtra
Tel: 022-2764 1585, Mob: 9821334822
Email: [email protected]
Website: www.hildaautomation.com
Packaging machineThe Corazza automated packaging
machine is used for processed cheese,
butter and soft soup cubes. This
machine is versatile for a wide range
of applications, for products in any
required shapes having delicate
consistency and requiring high-speed dosing, wrapping and cartoning,
eg, processed cheese, fresh & cream cheese, dosed hot or cold. The
machine has greater sealing coverage with patented tear tape offering
far superior protection of the product.
Tricon
Pune - Maharashtra
Tel: 020-25652205
Mob: 09890192832
Email: [email protected]
PRODUCTS
98 Modern Packaging & Design July-August 2012
The information published in this section is as per the details furnished by the respective manufacturer/
distributor. In any case, it does not represent the views of
Food packaging equipmentThe food packaging
equipment includes jar
filling machines for pickles
and insulated bottle filling
tanks. These machines are
useful for bottle and high-
weight PET bottles filling
for mango, lemon, mix
pickles suitable for bottle
and jar filling machines.
Jar filling equipment with
125 kg filling hopper
have provision of suitable
nozzles. Regulated speed
motor is provided with auger filler. Blended pickle and fruits do
not get damaged. Weight filling is done by these machines and final
weight is achieved by oil topping.
Varada Engineers
Pune - Maharashtra
Tel: 020-26989087
Mob: 09823076601
Email: [email protected]
Website: www.foodequipmentvarada.com
Blow moulding machineThese b low
moulding machines
are targeted to
produce plastic
containers such as
bottles, drums, tanks
and other types of
containers with
volume in the range
of 20 ml to 220 ltr.
Also available in
continuous type, this blow moulding machine is used for containers
below 25 ltr. The accumulator die head-type blow moulding machine
is used for containers above 25 ltr.
Chen Way Machinery Co Ltd
Tainan City - Taiwan
Tel: +886-06-2434077, 2434079
Email: [email protected]
Website: www.chenway.com.tw
Automatic wrapperThe model WM-4000-B
automatic wrapper is
good for packing house.
It has a 10.4' colour
LCD touch panel,
automatic film changing,
detachable and washable
in-feed table and lifts.
This automatic wrapper
also includes automatic
tray identification
and centering, f ree-
arm labeling and has
the capacity of 35 packs/min. The CCD camera automatically
identifies the tray as soon as it is placed on the in-feed table.
Wrapping conditions and tare weight are set automatically and
any fluctuation in commodity tray placement is corrected by the
centring conveyor.
Ishida India Pvt Ltd
Gurgaon - Haryana
Tel: 0124-3854392, Mob: 09971449821
Email: [email protected]
Website: www.ishidaindia.co.in
LIST OF PRODUCTS
Modern Packaging & Design July-August 2012 99
FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
Looking For A Specific Product?Searching and sourcing products were never so easy.
Just type MPD (space) Product Name and send it to 51818eg. MPD Wrapper and send it to 51818
Auto sealer series .......................................................96
Automatic extrusion blow moulding machine ................. 93
Automatic wrapper ........................................................... 98
Automation controllers .................................................... 23
Bearings ..................................................................... 4
Blow moulding machine ............................................. 97,98
Bottle/container filling machines ..................................... 98
Bottle testing equipment .................................................. 94
Breath analyser ................................................................. 95
Cable carrier ............................................................... 4
Cable connector ................................................................. 4
Cartoning machine.................................................. 98, FIC
Case erector ...................................................................... 95
Chain .................................................................................. 4
Chain pulley block ........................................................... 95
Chiller .............................................................................. 67
Co-extrusion blow moulding machines ........................... 93
Cold form sections ........................................................... 57
Compact pneumatic cylinder ........................................... 41
Concrete block & paver machines ................................ FIC
Connector ........................................................................... 4
Container filling lines ................................................... FIC
Conveyer belts .................................................................. 15
Coolant pipe ..................................................................... 59
Crabs/end carriages .......................................................... 95
Crane ................................................................................ 95
Digital temperature controller ....................................97
Dosing/sealing systems .................................................... 98
Drives ................................................................... 13, 23, 97
Dry vacuum pumps .......................................................... 96
Dual channel with modbus .............................................. 97
Dynamic controller .......................................................... 97
Eco wrap bagging machines .......................................47
Electric actuator & gripper .............................................. 41
EOT/HOT cranes ........................................................... 95
Exhibition - International Packtech India 2012 ................ 8
Expanded polyethylene capseals ......................................... 3
Expanded polyethylene seal liners...................................... 3
Extra heavy-duty bagging machines ................................ 47
Filing & packaging ....................................................39
Fill and seal machines ...................................................... 40
Flame-proof hoist ............................................................ 95
Flexible packaging material .............................................. 40
Flushing and sealing machine .......................................... 96
Food packaging equipment .............................................. 98
Gaskets ...................................................................... 3
Gearboxes ......................................................................... 95
Goliath crane .................................................................... 95
Goods lift ......................................................................... 95
Guided compact pneumatic cylinder ............................... 41
Hand-type impulse sealer ...........................................96
Heavy industrial steel structures ...................................... 57
HMI ................................................................................. 23
Horizontal FFS ............................................................. FIC
Horizontal flow wrap machine ........................................ 47
Horizontal form-fill-seal machines .................................. 98
Hydrogen gas detection system........................................ 94
Induction cap sealer ...................................................96
Induction motors .............................................................. 23
Invospeed.......................................................................... 93
JIB crane ...................................................................95
Labeling .................................................................. BC
Labeling machines ...................................................... 40,97
Linear weigh fillers .......................................................... 96
Liners ................................................................................. 3
Long bar sealer ................................................................. 96
Material testing instrument ........................................94
Metallocene polyethylene ................................................... 6
Monoblock high-vacuum pump ...................................... 96
Monorail trolley ............................................................... 95
Motorised chain pulley block ........................................... 95
Motors .............................................................................. 19
Multilevel steel car parks ................................................. 57
Nitrogen extrusion sealer ...........................................96
Non-nozzle-type vacuum sealer ....................................... 96
Nozzle-type vacuum sealer ............................................... 96
Oil cooler ..................................................................67
Oil seal high-vacuum pump ............................................. 96
Packaging machine ....................................................97
Packaging solutions .......................................................... 65
Palletisers ................................................................. FIC, 98
Panel cooler ...................................................................... 67
PET bottle testing equipment ......................................... 94
Plastic film & sheet.......................................................... 40
Plastic masterbatches ....................................................BIC
PLC .................................................................................. 97
Pneumatic bagging machines ........................................... 47
Polyethylene ....................................................................... 6
Pre-engineered metal buildings ........................................ 57
Pressure guage .................................................................. 59
Pressure sensor for wet packaging application ................. 31
Profile controller ............................................................... 97
PU tube ............................................................................ 59
Pumps............................................................................... 96
Push fittings ..................................................................... 59
PVC flexible braided hose ............................................... 59
Refrigerated compressed air dryer ...............................41
Roofing & cladding sheets ............................................... 57
Roots vacuum pumps ....................................................... 96
Rotary pumps ................................................................... 96
Sachet pacer ...............................................................47
Semi-automatic filling system .......................................... 47
Sensors ............................................................................. 51
Servo motors .................................................................... 23
Shrink film ................................................................40, BC
Shrink wrap sealer series .................................................. 96
Shrink wrappers ............................................................... 40
Single-stage monoblock vacuum pump ........................... 96
Single-stage vacuum pump .............................................. 96
Skin wrapping ...........................................................BC, 40
Sleeve wrapping machine ................................................. 93
Solenoid valve .................................................................. 59
Structural floor decking sheets ......................................... 57
Temperature controller ..............................................97
Testing instrument ........................................................... 94
Textile packaging boxes .................................................... 95
Thermoform-fill-seal machine ......................................... 94
Thermoforming moulds ................................................... 94
Thunder continuous motion bagging machines .............. 47
Transfer trolley ................................................................. 95
Tubular bag form ............................................................. 40
Two-stage vacuum pump ................................................. 96
Universal controller....................................................97
Vacuum pumps ..........................................................96
Vertical FFS .................................................................. FIC
Vertical form-fill-seal machines ...................................... 98
Wire rope hoist ..........................................................95
Product Pg No Product Pg No Product Pg No
LIST OF ADVERTISERS
100 Modern Packaging & Design July-August 2012
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
Our consistent advertisers
Benison & Co. Ltd. 40
T: +886-3-322-5531
W: www.benison.com.tw
Bharat Bijlee Ltd 23
T: +91-22-24306237
W: www.bharatbijlee.com
Bonfiglioli Transmissions (Pvt) Ltd 13
T: +91-44-24781035
W: www.bonfiglioliindia.com
Cognex Sensors India Pvt Ltd 51
T: +91-20-40147840
W: www.cognex.com
Exxonmobil Chemical 6
T: +86-21-2417-3999
W: www.exxonmobilchemical.com
Freeze Tech Equipments Pvt Ltd 67
T: +91-44-42152387
W: www.freezetechequip.com
Heat And Control 17
T: +91-44-42103950
W: www.heatandcontrol.com
IFM Electronics India Pvt Ltd 31
T: +91-2312672770
W: www.ifm-electronic.in
Igus India Pvt Ltd 4
T: +91-80-39127800
W: www.igus.in
Infomedia India Ltd. 89
T: +91-22-30034650
W: www.mphonline.in
Joyam Engineers & Consultants Pvt Ltd 96
T: +91-79-26569533
W: www.joyamvactech.com
KHS Machinery Pvt. Ltd 39
T: +91-79-2644-0331
W: www.khs.com/india
Messe Dusseldorf India Pvt Ltd 8
T: +91-11-26971745
W: www.md-india.com
Mifa Systems 97
T: +91-79-26870825
W: www.mifasystems.com
Nichrome India Ltd 65
T: +91-20-6601101
W: www.nichrome.com
Pakona Engineers India Pvt Ltd FIC
T: +91-22-22826751
W: www.pakona.com
Prayag Polytech Pvt Ltd BIC
T: +91-11-47262000
W: www.prayagmb.com
Presto Stantest Pvt Ltd 94
T: +91-129-4085000
W: www.prestogroup.com
Reynders Label Printing India Pvt Ltd 41
T: +91-149-3305400
W: www.reynders.com
Roechling Engineering Plastics (I) Ltd 98
T: +91-22-4217 8787
W: www.roechling-india.com
Shanghai Dase-Sing Packaging
Technology Co., Ltd BC
T: +86-21-3365-8333
W: www.dasesing.com
Techno Industries 95
T: +91-79-25830742
W: www.technoind.com
The Indian Electric Co 19
T: +91-20-24456062
W: www.indianelectric.com
Ultraplast Chainbelts Pvt. Ltd 15
T: +91-129-4113187
W: www.ultraplastindia.com
United Steel & Structurals Pvt. Ltd 57
T: +91-44-42321801
W: www.unitedstructurals.com
Universal Corporation 59
T: +91-22-23436320
W: www.samson-grp.com
Vora Packaging Pvt Ltd 3
T: +91-22-24012330
W: www.vorapack.com
Wraptech Machines Pvt Ltd 47
T: +91-22-27614316
W: www.wraptechmachines.com
Wu Hsing Electronics Co. Ltd. 96
T: +886-4-2271-1498
W: www.sealers-web.com
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