Protecting brand value with color consistency on pressSurya Fresh Foods installs KBA ‘dream machine’Surya Fresh Foods owners of the Priyagold biscuit brand has installed a ‘dream machine’ – a Rapida 105 6-color plus coater full UV press at its new carton plant at Surajpur in Greater Noida. The Rapida 105 at Surya has three interdeck and one end-of-press UV curing systems and is capable of printing 16,000 sheets an hour. The sheets are converted to monocartons for biscuits by a Bobst Novacut 106 diecutter and the Bobst Lila 106 A2 folder-gluer. Litho-laminated microflute cartons are produced using a Chinese sheet laminator from Boagang Machinery. A separate area houses the corrugation plant for secondary packaging. BP Agarwal, chairman, Surya Fresh Foods. Photo PSAThe in-house printing and packaging set up removes all critical issues of quality, timely delivery, operational flexibility and security. The 6-color UV KBA Rapida 105 is used by Surya to print CMYK and two special colors for their biscuit packs. “One of the special colors is our base color which could be blue, brown or orange and the other we use for our logo,” says Prasad. In addition to the Bobst Novacut 106 for diecutting, the Bobst Lila 106 A2 folder-gluer can produce both straight line and crash lock bottom boxes.
“We may require one more diecutter when the 105 KBA runs at full speed and at full capacity. Currently our monthly requirement is about 12 to 15 lakh sheets, which we can easily produce by running the KBA for a single shift and the diecutter in two shifts if necessary in situations of peak demand,” says Dinesh Prasad, plant manager, Packaging Division at Surya Fresh Foods. “We produce boxes of 6 to 7 sizes as per our requirements,” Prasad adds, “and the lack of consistency in quality was a major pain area. This led us to set up this in-house packaging unit.”