Sain Packaging’s Heidelberg CS 92 5-color plus coater

Healthy growth in pharma cartons

Sachin Gupta of Sain Packaging with his father (below) and son (left) along side the new Heidelberg 5-color sheeted offset press with coate. Photo PSA

Sonipat-based Sain Packaging recently installed its first new Heidelberg Speedmaster CS 92 5-color sheetfed offset press. The CS 92 press with inline coater is be produced exclusively in Heidelberg’s modern plant in Shanghai. A pharma packaging printer and converter, Sain Packaging uses FBB board in the 23 x 36-inch size, which makes the CS 92 with its 37-inch capability optimal for cost efficiencies.

“We print quantities as few as 100 cartons on our offset presses,” says Sachin Gupta, director of Sain Packaging. “We could opt for digital for proofing, but the print quality of a digital press and an offset press are not the same. That is the reason we use an offset press even for sampling work.

Initially, Sain Packaging operated from a small plant in Burari in North Delhi and has now migrated to a 65,000 square foot plant in Sonipat. It started with a single-color Adast Dominant and, within six months, purchased its next press, a used double-color Heidelberg. After years of running second-hand Heidelberg presses, it bought its first new Heidelberg for reasons of quality and wastage.

Reduction in plate cost and wastage with new Heidelberg CS 92

“In the packaging industry for monocartons, no other brand is as renowned as Heidelberg. Nevertheless, we were in talks with other press suppliers, but we preferred Heidelberg because we are already Heidelberg users. We bought the CS 92 because more than 99% of our work is in the pharma segment, and almost all our printing work fits well in the 25 x 37-inch format of this press. We will save at least Rs 1.5 lakhs a month on the plate cost,” he adds. Earlier, Sain Packaging wasted the equivalent of nearly 6 lakh sheets of board each month, which Gupta is hoping will come down to less than 50,000 sheets.

Currently, Sain Packaging has three 5-color sheetfed offset presses with coater, one 4-color offset press, and four double-color presses. “We purchased the new Heidelberg press not to increase capacity but to improve our quality and reduce wastage, which in turn will help us meet our delivery timelines,” Gupta explains. Each month, Sain Packaging converts 400 tons of board in round the clock operation amounting to nearly Rs 4 crore.

New trends in pharma packaging

According to Gupta, the pharma industry is witnessing tremendous growth. He says that earlier, pharma companies preferred inferior quality boards, and now every manufacturer is quality competitive, demanding the higher priced quality board stocks. While in the past 15 years, most pharma customers asked only for lamination for increased shelf-appeal, they are now asking for haptics such as textured UV effects and Braille.

Bobst for braille

“For Braille, we’re in talks with Bobst and are planning to buy a new folder gluer with inline Braille embossing. Currently, we experience demand for Braille only for exports, and we hope to grow the overseas market. Although we export more than 40% of our production, I’m pretty sure that Braille will become mandatory in India as well,” says Gupta. On the post-press side, Sain Packaging has two Bobst die-cutters, two Maxima die-cutters, three folder gluers, and nearly seven manual die-cutters. Sain Packaging supplies cartons and inserts to pharma companies in Baddi, Roorkee, Paonta Sahib, and Amritsar. It also has a small corrugation set up for internal consumption. Sain Packaging aims to achieve a Rs 100 crore turnover in the upcoming financial year.

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.

It is the right time to support our high-impact reporting and authoritative and technical information with some of the best correspondents in the industry. Readers can power Packaging South Asia’s balanced industry journalism and help sustain us by subscribing.

– Naresh Khanna

Subscribe Now


Please enter your comment!
Please enter your name here