Kalapi and Surat’s Sachin Corrugators to increase capacity with Bobst VisionFold

Two packaging specialists, Vasai-based Kalapi and Surat-based Sachin Corrugators & Printers are set to install Bobst’s VisionFold 110 A2 folder-gluer following which these companies expect to increase their folding and gluing service by 20% to 25%.

15 Apr 2019 | By Noel D'Cunha

Nanjee (c): “Kalapi is looking to address increasing niche packaging demand with VisionFold”

Kalapi’s clients demand
Kalapi’s NS Nanjee, partner of the company, said, we grew our folding and gluing capacity for our pharma packaging business after our investment in Bobst ExpertFold with Accubraille in 2011. “Accubraille was functionality that our customers had specified, and we provided that. Now we have projects for FMCG clients which require niche packaging products. The new VisionFold will help us address these increasing demands with ease.”

Nanjee cites Bobst’s proven technology and key advantages of VisionFold like the ease of set up, accuracy and consistent quality as reasons for continuing with Bobst though he did evaluate a number of machines with a lower initial investment cost. “We finally settled for the VisionFold. In today’s competitive business, it is pointless to waste time around production and machine issues.”

He added, “I have always believed in investing in equipment with proven technology which offers reliability and peace of mind, as an error on the folder-gluer results in a customer complaint and could lead to loss of a customer.”

Sachin Corrugators to expand carton packaging
The corrugated, litho-laminated micro-fluted and mono carton box manufacturer, Sachin Corrugators is a two-decade-old company based in Surat.
The company is equipped with a five- and two-colour Komori presses, an automatic die-cutter, flute laminator and hot foil stamping machine. Folding-gluing services were being outsourced.

Manjeet Dhariwal, director at Sachin Corrugators said, his company is now in the process of consolidating and modernising its printing and converting operations to bring all operations under one roof. “For the folding-gluing kit, we decided to partner with Bobst as we felt that it was very important for emerging players like us to adopt the right technology not only to cost competitive but also to have a vision of where we want to be in the next ten years.”

With the new investment, Sachin Corrugators will also be able to cater to both mono cartons and micro-fluted boxes demands from clients in the food, FMCG and textiles segments. “Our goal is to provide quality finished products, regardless of the complexities. For example, with the VisionFold we will be able to produce solid board, micro-flute options like E and F boxes and as well as liner cartons.”

Bobst Visionfold offers multiple capabilities for customers looking to process solid board, litho laminated corrugated and 4-6 corner boxes among others. The kit can run at a speed of up to 350m/min.

Dhariwal: “The in-house folding-gluing services will up our production by about 25%”

Currently, Sachin Corrugators converts about four tonnes of corrugation and six tonnes of paper boards per day. “By bringing the folding and gluing services in-house, we will be saving both times, which will up our production by at least 25% as well as waste,” said Dhariwal.

In addition, Sachin Corrugators are also investing in a four-line corrugation and flexo post-press machine, which will be supplied by Ample Graphics, as well as a packaging converting machine from Suba Solutions. “Going forward, we hope to double our capacity and take it to 10 tonnes of corrugation and 14 tonnes of paperboard conversion per day,” concluded Dhariwal.

Bobst has successfully installed its kit at new and emerging players in Gujarat in the last few years, especially in Surat. Weepac was one of the first packaging companies in Surat to install a Bobst NovaCut 106 die-cutter and a VisionFold 110 with four- and six-corner attachments and a plastic kit.

“We feel Surat will become a major hub for manufacture and supply of quality packaging for various emerging brands in the western part of the country.” 

He added, “Bobst has a large presence in India. It’s a global manufacturing facility in Pune and experienced process specialist having know how in folding gluing process is always there to hand hold and support new and emerging players in the folding carton business and we believe that our customers’ success is our success.”