Mumbai-based Kalpataru Cartons recently ventured into packaging segment to meet the growing demand for crash lock cartons for their pharma clients. Sameer Pingulkar, director of Kalpataru Cartons, started off with production of commercial products at its unit near Mumbai-Nashik highway.
On realizing the need of having an altogether different inventory, he opened another unit next to the existing Asangaon one. The new state-of-the-art facility is spread across 15,000 sq. ft. Having two units at close proximity helped in utilizing the 50 employees in the company optimally. “We are also close to Bhiwandi, which is a hub for warehouses and an ideal location to distribute our finished products anywhere within and outside the country, due to its proximity to Jawaharlal Nehru Port Trust (JNPT)—the largest port in India. The maximum caliber of the air-conditioned unit is around 60,000 sheets a day, and recently, they installed a Supersport carton inspection system,” he says.
He adds, “With an intention to find a solution for manual carton sorting, we got in touch with Pratham at drupa 2012. Pratham offers a unique solution in the offline inspection system for pharma carton manufacturers. Supersort 5003 carton inspection system has been developed in collaboration with Germany-based Vision Experts—a leader in print inspection system that enables 100% monitoring and documentation of print quality for the entire print job. The 100% print inspection is based on complete coverage of the entire printed image due to the highspeed line scan cameras that provide the highest resolution. There are three cameras; while the top camera inspects for color deviation, surface scratches, spots, hickeys, mottles and text variations, the bottom camera is a monochrome one which examines dots, spots and a few others. With such a system, the rejection
rate would be over 40%, which is not beneficial to a carton manufacturer. Rejected packages may be acceptable to the client, and we need to calibrate the machine in order to set different benchmarks for different customers. This device isn’t meant to reduce wastage. However, having documents against the reasons for rejection can help us evaluate the reasons, thereby helping our unit to become more efficient in near future.”
The new unit comprises of Heidelberg 6 color + dual coating system, Bobst SP 106, folder-gluer system from Jagenberg, and ink matching kitchen to generate specific Pantone colors. Going forward, Kalpataru Cartons plans to expand its services to FMCG companies as well as set up a prepress unit.