B&B Triplewall regains corrugated world production record

Greater automation with Bobst flexo folder gluer marks achievement

B&B Triplewall
B&B Triplewall's Bobst FFG Discovery used for setting the new 8-hour world production record Photo Bobst

On 27 May 2020, B&B Triplewall – a leading manufacturer of quality corrugated boxes in India attained an incredible production level of 142,611 boxes in just 8 hours, breaking (and regaining) the world record for corrugated box production. The company achieved this feat using an FFG 8.20 Discovery, a super-efficient Bobst flexo-folder-gluer.

“The record means a lot to us,” said Manish Gupta, chairman, and managing director at B&B Triplewall. “We actually held the record before, but it was surpassed by another company, so that gave us an extra incentive. The whole team was extremely motivated to achieve this, and I am so proud of everyone for going the extra mile, particularly during such a challenging time.”

B&B Triplewall with its headquarters in Bengaluru and factory in Hosur, has stringent safety measures to ensure the safety of its staff during the COVID-19 pandemic, including social distancing measures, mandatory masks, hand washing and sanitization, and temperature checks. But when two large orders came in with the same delivery timeframe, Gupta and his team knew they could make the record attempt while ensuring the safety of their employees.

“Our employees are our biggest asset,” he explained. “Ensuring their safety and happiness is paramount to us. I believe that is why we are so effective as a team and able to serve our customers so effectively. I believe that our focus on our employees is a key reason why we have such an incredible history of customer retention and why we were able to achieve this record.”

B&B Triplewall's winning team Photo Bobst
B&B Triplewall’s winning team Photo Bobst

Utilizing state-of-the-art technology to stay ahead of the curve

Gupta, who has been in the corrugated industry for more than 20 years, founded B&B with a business partner in 2012. The company merged with HMK Autopacks Private Limited in 2016 and has since gone from strength to strength. The company’s stated aim is to be number one in India in terms of sales volumes soon.

“The Indian Market is quickly evolving in terms of technology, scale, and quality,” he said. “To be at the forefront of this evolution means a lot to us. We always try to remain future-proof. One of the biggest trends for the future of packaging is greater automation, and we are already one of the most automated factories in India.”

The Bobst FFG 8.20 Discovery, which was used to set the world record, boasts high automation levels. It is known in the industry for maintaining accuracy and quality at high speed, with fully automated, high-quality folding. It is a user-friendly machine with an intuitive man-machine interface, robust, with low maintenance needs.

“The software and automated features on the FFG 8.20 make it easy to use – operators do not need to be highly qualified, and it is simple to train people to use the machine,” said Gupta. “It is perfect for eCommerce and FMCG, which make up a large part of our business. We produce up to 4 million boxes a month with this machine, which is excellent.”

Great minds think alike – another FFG

Since B&B Triplewall installed the FFG 8.20 Discovery in 2017, the relationship between the company and Bobst has flourished. In 2019, Triplewall decided to invest in another Bobst flexo folder gluer to increase capacity even further – the FFG 924 NT.

“One of the main reasons we chose the FFG 924 NT is because we were extremely happy with the FFG 8.20 and the level of service we received from Bobst,” said Gupta. “They have a local manufacturing branch in India, who have been extremely responsive to all our requirements. The level of quality and knowledge of the Bobst technicians is excellent, and makes things much easier for us”.

The FFG 924 NT is designed to produce all types of boxes from standard RSC up to full die-cut and high graphics – a true ‘three in one’ machine. B&B Triplewall has identified high graphics as a critical area of growth in the Indian market, and the FFG 924 NT ticked this box as well as all the others the company needed. FFG 924 NT achieves – in one pass – first-class printing, excellent die-cutting, and accurate folding, and is a step ahead in terms of flexibility. It is also associated with shorter set-up times and fewer stoppages, with easy change and cleaning of the anilox rollers. The production level of the machine can reach approximately 140,000 square meters of corrugated board per day.

For Gupta, adding such state-of-the-art equipment to his factory floor helps him realize his vision for the company – to provide perfection for his customers and ensure that every product his company delivers is uniquely crafted to the customer’s desired needs.

“This job is a passion for me,” he said. “Every day, my focus is on making a positive difference for our customers and our employees. A partner like Bobst, which is similarly focused on providing the highest quality and staying ahead of the curve when it comes to packaging trends, helps us achieve our goal. This world record is proof of that.”

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital 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.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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– Naresh Khanna

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