Modern Packaging & Design - July-August 2012

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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


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

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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

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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.


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


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


NEWS, VIEWS & ANALYSIS


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



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



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


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


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


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


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��_��

Z�� z!��q��+++_��\��_��+��!��_�� q�� q��]��'�� '�+�'!��and seekers of technologies across the globe. After submitting technology offer ��z!��+'��!��z!��+�� +��+{�� ]�� q�� q��q��]�'!��|��{�� !�� +'��before contacting APCTT for further assistance.

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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.

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Technology Requested

IN CONVERSATION WITH: A j i t S ingh


…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


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,

‘Modern Packaging & Design’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the packaging industry.

You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words.

The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format.

The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Packaging & Design’. Authors whose articles are published will be sent a complimentary copy of that particular edition.

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.

So get going and rush your articles, write-ups, etc…

Look forward to hearing from you, soon!

Yours sincerely,

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Business InsightsTechnologies

Opportunities

ANNIVERSARY SPECIAL


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


ANNIVERSARY SPECIAL

‘Pack’ing a punch with innovation

DESIGN: CAD/CAM technology


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


Cou

rtes

y: A

very

Den

niso

n

DESIGN: CAD/CAM technology

CAD/CAM technology


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.


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.


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.


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


“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.


…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


“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.


…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


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?


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-


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


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.


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.


Courtesy: H

imalayan G

roup of

Industries

MATERIALS: F lex ib le packaging


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


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.



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.



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.


…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


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?


MACHINERY: Robot ic pal let iser


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


MACHINERY: Robot ic pal let iser

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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


Conveying flexibility and speed

MACHINERY: Conveyor technology

Courtesy: KHS GmbH


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.


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


“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.


MACHINERY: Inter face - Avra Mitra


“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.


…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,


LOGISTICS: Packaging for cold chain

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Packaging for cold chain


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.


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.”


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LOGISTICS: Reverse supply chain


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


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.”


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.


LOGISTICS: Inter face - Frank Ol iver i


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.


“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


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?


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


SAFET Y: Fresh food packaging

Fresh food packaging


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.


& 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.


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


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


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.


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.


“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.


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.


“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.


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


SECURIT Y: Brand protect ion

Cou

rtes

y: A

very

Den

niso

n

Brand protect ion


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.


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.


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


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


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.


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


SECURIT Y: Inter face - Kar l Vandenbussche


“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.


…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


“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.


…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


SUSTAINABILIT Y: Packaging mater ia l

Cou

rtes

y: B

orea

lis A

G

Packaging mater ia l


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.


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.”


SUSTAINABILIT Y: Reducing Reducing carbon Footpr int


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


SUSTAINABILIT Y: Reducing Carbon Footpr int

Reducing Carbon Footpr int


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.


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


“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.


…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


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


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


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


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


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


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.


PROJECTS


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


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


Packaging machinery and technologyPaharpur Industries Ltd


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 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


Printing institute cum testing laboratory projectThe North India Printers Association

(NIPA)


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 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


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


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


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


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


Narendar Bafna

Smart Expos

New No 116, Mount Road

Guindy, Chennai - 600 032

Tel: 044-22501986/1987

Mob: 09952966752


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


Cyril Pereira

25, 3rd Floor, 8th Main Road

Vasanthnagar, Bengaluru - 560 052

Tel: 080-4330402, Mob: 09886789641

Fax: 080-22352772


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


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


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


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


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


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


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


Rajesh Nair

Exhibition Manager

Al Fajer Information & Services

PO Box: 11183, Dubai, UAE

Tel: +971-4-3406888, Fax: +971-4-3403608


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


Japan Packaging Institute

10F Togeki, Bldg 4-1-1

Tsukiji, Chuo-ku, Tokyo - 104 0045, Japan

Tel: +81-3-35431189, Fax: +81-3-35438970


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


Adrian Harrow

easyFairs UK Ltd

8 Oak Lane, Twickenham TW1 3PA

United Kingdom

Tel: +44 (0)20-88438800

Fax: +44 (0)20-88921929


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


Jim Beretta

UBM Canon

11444 W. Olympic Boulevard

Los Angeles, CA 90064-1549 USA

Tel: +310-445-4200, Fax: +310-996-9499


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


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


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


Krista Exhibitions

Blandogan Street

No 28 D/G - Jakarta 11220

Tel: +62-21-6345861/62

Fax: +62-21-6340140


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


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.


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


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



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


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


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


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


Website: www.full-shine.com

PRODUCTS


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


Tel: 022-66971133

Mob: 9967752336


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


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


Website: www.indvacindia.com

PRODUCTS


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


Tel: 022-28596422


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


Tel: 022-26818628, 26818888

Mob: 8980011640


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


Tel: 022-22854138


Website: www.pakona.com

PRODUCTS


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


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


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


Tel: 022-24451709


Website: www.arshadelectronics.in

PRODUCTS


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


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


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


PRODUCTS


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


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


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


Website: www.ishidaindia.co.in

LIST OF PRODUCTS


FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover


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


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

E: [email protected]

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

FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

COMPLETE ENGINEERING UNDER ONE ROOF @www.eng-expo.com

Documents

Modern Packaging & Design - July-August 2012