Sain Packaging to install its first Roland 700 Evolution

Sets eyes on liquor, cosmetics, and hosiery segments

Sain Packaging
(L-R) Sanchit and Sachin Gupta with the Heidelberg CS-92 5-color with coater at the Sain Packaging plant in Rai, Sonipat. Photo PSA

Based on advice from one of his friends, Sachin Gupta started Sain Packaging in 2004. The company, which began with a small investment in a tiny 400-square-yard plot owned by its managing director Gupta, shifted to Rai in Sonepat in the Delhi NCR, in 2005. The friend’s advice has proven to be sound as the company moved once again in 2016 to bigger premises – its present location spread over an ample 2,500 square yards. In addition, it recently acquired an adjoining plot of land measuring 1,500 square yards.

Sain Packaging started by producing monocartons for the pharma industry. Eventually, it branched out to lingerie, food, and electrical product packaging. Yakult is one of the big new food brands that it has recently serviced with packaging materials.

Zero rejection on the new multicolor press purchased two years ago

Gupta recounts, “Two years ago, we purchased a brand new Heidelberg CS-92 5-color with coater (March 2020) as we had only used second-hand machines earlier. After acquiring the new press, our point of view regarding packaging machines changed completely. We are working on zero defects now – we print 1,25,000 to 1,50,000 sheets daily on that machine and there is zero rejection, including color rejection. We have two other second-hand Heidelberg presses – one a Heidelberg CPtronic 4-color and the second a Heidelberg CD102 5-color plus coater – but the new CS-92 5-color with coater has 5 times their production in comparison. There is no match to the new press, quality-wise.”

Sain Packaging
Sachin Gupta at the Sain Packaging office in Rai, Sonipat. Photo PSA

We have recently purchased a new Manroland 700 Evolution 7-color with coater to replace the two older Heidelberg presses in operation at our plant. These days, monocarton packaging has moved to UV and coating-based textures that are being printed and cured inline – that we have so far been doing offline. With the Manroland press, we will be able to do this work inline, which will reduce our lead times by 3 to 4 days and help control the wastage. We hope to greatly reduce our maintenance costs to zero. On average, there is a substantial monthly maintenance cost on our old machines.”

“We compared the presses from leading companies such as Heidelberg, Komori, KBA, and Manroland Sheetfed and after a thorough analysis and 1.5 months of comparisons, we zeroed in on the Manroland. The Heidelberg machines are being manufactured in China while the Manroland Sheetfed presses are entirely German manufactured. We also found the Manroland machines to be superior in terms of configuration.”

“We were impressed after interacting with Peter Rego (director of sales and business development at Manroland Sheetfed India) because he led Heidelberg to a top position in India through his diligent after-sales support. Manroland had not installed a new press in India in the last three years. As we are among the first customers to acquire the Roland 700 Evolution press, we are expecting impeccable service support from them.”

Increasing volumes and turnover

Leeford Healthcare from Ludhiana, Amritsar-based Quality Pharmaceuticals, and Sonepat-based Combitic Global Caplet are some of the leading pharmaceutical companies that rely on Sain Packaging for monocartons, pharma inserts, and corrugated packaging for pharmaceutical products. The company closed the last financial year with a turnover of Rs 62 crore and has sights on its turnover crossing Rs 150 crore turnover this year. “Our turnover will increase drastically after the installation of the Roland 700 Evolution press in December. Our wastage and maintenance costs will reduce while the turnaround time and quality will improve. As this machine has the all-important UV curing capability, we are targeting the liquor and cosmetics segments as well. After the Manroland installation, we will become a complete packaging house. Packaging has tremendous scope and we are eyeing bigger clients.”

Sain Packaging
Monocartons produced at the Sain Packaging plant in Sonipat. Photo PSA

“Most of the presses in India have the 28 x 40-inch size while the Roland 700 Evolution press offers 29 x 41.5-inches, which is specifically advantageous to us as this size is appropriate for monocartons in the lingerie and hosiery segment. This size difference opens up a world of opportunities for us,” explains Gupta.

Sain Packaging has greatly improved its corrugated packaging operations during and after the Covid-19 pandemic. The company purchased a Bobst Expertfold folder gluer with a Baumer HHS gluing gun and online inspection system in 2021, along with the Esko automation engine software to automate its prepress and production process workflow. 

“The impact of the single-use plastic ban is gradually showing in the Indian packaging industry. However, due to the political upheavals such as the Ukraine War and natural disasters such as floods in Canada, paper prices have almost doubled which has, in turn, increased the working capital requirements,” Gupta observes.

Although it is widely seen that the younger generations of printers and packagers don’t opt for the family business, Gupta’s son Sanchit has proved to be an anchor of support and stood by him during the ups and downs of the pandemic in the last two years. Gupta asserts that Sanchit has learned the ropes of the packaging business on his own accord, and plans to join the business after completing his studies in the UK. 

2023 promises an interesting ride for print in India

Indian Printer and Publisher founded in 1979 is the oldest B2B trade publication in the multi-platform and multi-channel IPPGroup. While the print and packaging industries have been resilient in the past 33 months since the pandemic lockdown of 25 March 2020, the commercial printing and newspaper industries have yet to recover their pre-Covid trajectory.

The fragmented commercial printing industry faces substantial challenges as does the newspaper industry. While digital short-run printing and the signage industry seem to be recovering a bit faster, ultimately their growth will also be moderated by the progress of the overall economy. On the other hand book printing exports are doing well but they too face several supply-chain and logistics challenges.

The price of publication papers including newsprint has been high in the past year while availability is diminished by several mills shutting down their publication paper and newsprint machines in the past four years. Indian paper mills are also exporting many types of paper and have raised prices for Indian printers. To some extent, this has helped in the recovery of the digital printing industry with its on-demand short-run and low-wastage paradigm.

Ultimately digital print and other digital channels will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future. For instance, there is no alternative to a rise in textbook consumption but this segment will only reach normality in the next financial year beginning on 1 April 2023.

Thus while the new normal is a moving target and many commercial printers look to diversification, we believe that our target audiences may shift and change. Like them, we will also have to adapt with agility to keep up with their business and technical information needs.

Our 2023 media kit is ready, and it is the right time to take stock and reconnect with your potential markets and customers. Print is the glue for the growth of liberal education, new industry, and an emerging economy. We seek your participation in what promises to be an interesting ride.

– Naresh Khanna

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