Vijayneha Polymers inaugurates new flexible packaging plant

Flexible packaging produced for leading make owners by Vijayneha Polymers. Photo: Vijayneha

Shardul Sharma with inputs from Naresh Khanna

Hyderabad-based Vijayneha Polymers officially inaugurated its huge and ultra-modernistic flexible packaging plant on 17 January 2022 in the presence of its customers, machine suppliers, raw material providers and bankers. The chief guest for the consequence was Jayesh Ranjan, main secretary to the regime of Telangana, who cut the ribbon. The institute has been in operation since October 2018.

Located near 90-minutes from the city, the plant has top-of-the-line machinery in the motion picture-extrusion, printing and finishing departments. It houses two printing presses from W&H, a Heliostar Due south rotogravure press and a Miraflex A CI flexo press. W&H has supplied a 3-layer blown moving picture extrusion line and a 7-layer blown film extrusion line besides. Along with these, the plant has three slitter rewinders: two ER610s from Atlas-Titan and one Roboslit RL from SP Ultraflex. Vijayneha employs two laminators from Nordmeccanica – a Super Combi 4000 laminator and a Simplex SL compact laminator. A Worldly WCL-H-1300 co-extrusion coating and laminating car is besides installed in the plant.

Information technology is the abyss or comprehensiveness of the new plant that reveals its intention of being totally world class. Autonomously from the airtight loop systems on the presses, there are extensive quality checking machines and a big laboratory for testing materials. A complete and separate room houses a consummate set of automated equipment for cleaning and maintaining cylinders, plates and anilox rollers. The anilox cleaner, plate washer, automatic cylinder cleaner, parts washer and distillation unit are all from Flexo Wash. The company is planning to have an in-business firm cylinder-making sectionalization only has no plans for an in-business firm flexo plate making division.

Doc Shiv Kumar Gupta and Kaushik Nag with i of the 2 new Varex flick lines provided by Due west&H. Photo PSA

The promoter and managing director of Vijayneha Polymers, Shiv Kumar Gupta has more two decades of experience in the plastic processing industry. "One good thing about plastic in Republic of india is that information technology has growth, it has never shown de-growth," he says.

Gupta is optimistic about the new plant's prospects for growth and success. He believes that whatever brand owner who visits new plant volition appreciate both its actuality and its intention. Acknowledging that at this stage he will be establishing volumes and conviction in his customers, he is quite sure of eventually reaching that part of the value chain that will be more profitable. He believes that diverse regulations including the waste matter management rules are disruptions that will help the industry and Vijayneha in its growth. He is emphatic that apart from technology the right manpower is essential. "We have the best!" he says.

He says that the company is already working with several make owners in the development of sustainable packaging nether non-disclosure agreements. In addition, Gupta has several serious and interesting plans for recycling of plastic waste on an industrial scale.

Many of Gupta'due south ideas are echoed by Kaushik Nag director and principal executive officer of Vijayneha Polymers, "Right from the start, the company management has a very clear vision to go up the value chain. These top-of-the-line equipment put us on a platform which is manner across the imagination of electric current players in the market. We were always going to go for the best." Nag also says that Vijayneha has not only worked on getting the best hardware but has invested as in getting best human capital from all beyond the flexible packaging industry. "In the finish it is the workforce that runs the show and we take made certain we have the best of that as well," he states.

Amidst the extensive acme-of-the-line machinery and ancillary equipment that the company has installed at the plant, W&H extrusion lines and presses are the centrepieces. Talking nearly the partnership with W&H, Nag says, "In the current market that is rife with competition, the best mode to stay ahead is to invest in technology that gives you an edge — technology that helps you in achieving the desired output with minimal wastage and maximum consistency. I feel West&H offers all these."

Doubling capacity by 2020

To start with, the new plant will have an installed capacity of two,000 tons per month and is expected to operate at 80%-85% capacity. According to Nag, the capacity of the plant volition exist increased by another 2,000 tons per month by 2020. "The adjacent phase of the expansion will see a similar kind of investment in mechanism and applied science, a replica of sorts of what we have today," he shares.

In terms of customers, Vijayneha will be servicing more often than not those customers who take loftier volumes such as big domestic and global brands. Most 70% of the output will exist supplied domestically and thirty% will be exported, mainly to Europe and North America. "The bulk of our clients will be those with large volumes as yous demand to justify this level of investment and scale by dealing in big volumes," he argues.

Sustainability and CI flexo

In recent years, more than and more of the leading flexible packaging convertors have opted for flexo printing technology. Vijayneha too has gone in for a CI flexo press along with a gravure press. Nag says that the idea behind having these two printing technologies under one roof was to make certain that Vijayneha is able to service all types of customer demands right from the start. The intention is as well to be capable of producing high quality PE/PE laminates and packaging suitable for salt, pulses and dry appurtenances that are easier to recycle. Correct from the get-go, the new plant only uses non-toluene and non-MEK inks.

"The gravure press will be used for press flexible packaging materials that volition be used to pack solid items such as biscuits and wafers while the CI flexo press will be used to print material used in packaging liquid items such equally edible oils and milk," he says. Nag believes that the footprint of flexo presses will go along to expand in Bharat thanks to significant improvements in the prepress, printing, inks and anilox technologies. "I am sure that that CI flexo technology will play a much bigger role in the Indian flexible packaging industry in coming years," he concludes.

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