Asepto in Sanand – For liquid food and beverage packaging
In 2018, nosotros had an opportunity to visit the brand new Uflex Asepto plant in Sanand in the land of Gujarat in Western India. At the time, we didn't really have an idea of what to await although nosotros knew it was a big greenfield project for liquid nutrient packaging and that it used a Gallus broad web flexo printing. Now every bit we write, the plant has completed a full year of commercial production.
In our meeting with Ashwini Sharma, president and principal executive officer of New Business Initiatives at Uflex, in June, he updated united states of america on the Asepto project, "The initial stages of the investment accept been encouraging. We take adept brands under our belt and the proficient part is that the new brands are seriously exploring doing business organisation with us. We offer an attractive product to the market and people see a lot of value in what we practice."
Sharma says the liquid packaging market in India is over ten billion packs, adding, "Last year'south growth was 17% and this year we see the growth rate improving. The 3 large consumption segments in India are non-alcoholic beverages, alcoholic beverages and dairy products. In the beverage segments, healthy drinks seem to be pop. . . Our converting institute is designed with a capacity of vii billion packs just at nowadays our maximum converting capacity is 3.five. billion packs." Designed for growth, Asepto's converting chapters can be augmented or optimized when viable with minimal additional capex on the infrastructure.
Our visit to Sanand took place when brand owners were still conducting trials. The situation now has progressed to the extent that the Asepto laminate is being supplied to several make owners in the juice, dairy and alcobev segments. The Asepto laminate has besides already found export customers on other continents. In add-on, more than than half a dozen of the Asepto Smart 78 filling and sealing machines manufactured by Uflex's Engineering Division in Noida accept also been placed at customer sites.
According to Sharma, most of the Asepto customers are using the popular 200 ml packs. "When you expect at the drinkable market, over ninety% of potable is sold in portion packs of 200 ml, 165 ml and 100 ml, while the larger packs make up for a small percentage of the market. In the alcoholic potable segment, the 100 ml packs are growing in a big mode."
The Asepto WOW! factor
Sharma explains that the visitor has divided the market and devised strategies to deal with each segment separately, "What the customers want is to know how to build a brand and how to sell the maximum units. In order to practice that we created these holographic effects and commercialized the packs. Nobody in the world is using the foil stamping furnishings on liquid packaging pack that we are. It has a cost plain and initially customers may resist, but we are moving ahead and have brands such as Fresca and Juicico. Today our laminate is already running with top brands on loftier speed machines and we have over fifty customers. At the aforementioned time, our starting time shipment will run outside India this month."
The Asepto laminate sets itself apart from others because of its premiumization using a range of metallic and embossed decorative effects. Using a unique transfer technology, the laminates incorporate a range of metallized sparkling, shining and raised surfaces that evoke holographic and 3D effects. This premiumization is the Wow factor to brand Asepto a successful, value-added laminate provider. The effects are innovative considering they are done using only a 6-layer laminate.
The value-adds and metal effects accept already helped some of Asepto's dairy and juice brand customers such as Fresca to make their products stand out on the shelf. The premium metal and embossing combinations certainly add together a scrap of zing or Wow factor to the easy to behave, single serve and tamper-proof Asepto packs, which accept besides become pop for the sale and consumption of alcoholic beverages.
Producing the laminate
The objective of the Asepto establish is to provide laminate rolls that can be aseptically formed and filled by liquid food and beverage manufacturers on specially designed liquid filling and sealing machines such as the Asepto Smart 78 that is manufactured by the Uflex Engineering Segmentation in Noida. In club to ensure that the packaging is totally aseptic, these machines laissez passer the laminate through a hydrogen peroxide bathroom before the forming, filling and sealing operations. Sharma says, "We have already sold half-dozen filling and sealing machines; we are in the procedure of building some other three and we volition get-go building some other one soon. We are receiving enquiries in the commercial segment from outside India for the laminate and the machines equally well."
Asepto's laminate for aseptic liquid nutrient and potable packaging consists of six layers. The elevation layer is a protective PE layer and the 2d layer, which gives the package its shape, stand-up and stackable stiffness, is made of paperboard that is imported from the BillerudKorsnas and Stora Enso paper mills in Sweden. The 3rd layer is of aluminum foil, which provides boosted high-level oxygen, wet and light bulwark properties. The quaternary is a PE necktie-layer which binds the outer layers of the blended laminate to the inner 5th and 6th layers of PE.
The printed decoration of the paperboard layer of the laminate is done on a vii-colour Gallus Intro 1320 mm wide unit of measurement to unit flexo printing capable of running at 500 meters a minute and equipped with a Martin Automatic unwinder, autosplicer and rewinder. Regarding the applied science, Sharma says, "For this particular flexo awarding, yous demand to have a high-terminate machine and Gallus is the all-time machine today that money tin can buy. In the liquid packaging segment, Gallus is undisputedly the all-time machine."
The Gallus press contains an inline tooling unit of measurement that is used for creasing, perforation and punching the holes required for the use of straws with many of the beverage products. Water-based flexo inks designed for food laminate production are provided past DIC, which as well has an ink kitchen within the plant.
As Manoj Nair, the vice president of operations at Asepto, explained to united states in Sanand, "The half dozen-layer construction is assembled on a Davis Standard extrusion laminator in one go. This machine has been time to come enabled with an unwinder for films also. Slitting and rewinding is done on an IMS Goebel slitter-rewinder, which produces the standard reels for the Asepto Smart 78 filling and sealing machines or those of other manufacturers." The standard slit reels of laminate are stacked on pallets and wrapped by an automated robotic logistics system from ITW Signode with 16 stations helping to maintain the stop-to-end hygiene of the process.
Best practices including the ISO 22000 Food Safety Guidelines and the BRC Issue 5 standards are maintained. Apart from these, at that place is an integrated quality direction arrangement. The plant as well has ISO 9001, 14001 and 18001 certifications. The well-equipped lab maintains the globally accepted production quality standards at the Sanand establish with measuring instruments from L&W and Instron and more than a dozen others. All the process owners at the Sanand plant and key machine operators take rich experience in the liquid packaging manufacture and take contributed significantly in establishing the unique Asepto laminate in the market.
Additionally, Asepto has built upwards potent engineering and technical teams in Delhi, Mumbai and Bengaluru for servicing its Smart 78 liquid packaging filling and sealing machines. The Engineering Segmentation in Noida, which manufactures the filling and sealing car, also contains a demonstration machine as well as a testing laboratory for proving the total efficacy and performance of the laminate and packaging. Materials are also periodically sent to internationally approved labs for establishing globally accepted norms and certifications for the laminate and the procedure. z
Elegant industrial architecture
When we arrived at the Asepto institute in Sanand, about 75 minutes past from Ahmedabad airport, we were surprised past the project's magnitude and its purpose-built but imaginative architecture. The two main structures and their service spaces utilise up approximately 22 acres of the 72-acre site. The architecturally stunning 100,000 square foot glass-walled executive block of the Asepto plant with landscaping and a fountain offset come into view. The 2 buildings make upward a total of 400,000 square anxiety of extremely modern and purpose-congenital industrial spaces.
A production block of 300,000 square feet contains the raw materials and finished goods stores, services, press, laminating, slitting and rewinding machines, materials testing and quality command laboratory and automated logistics. The space is completely air-conditioned and hygienically maintained to continue the microbiological load of the production environment to global standards. Designed for growth, converting capacity tin exist added or optimized with minimal boosted capex on the infrastructure. The Asepto liquid packaging constitute is the first major slice in the 72-acre Uflex site. The 72-acre site itself tin adjust three or four such plants depending on the company's growth strategy.
Anantshree Chaturvedi on the Uflex Asepto project in Sanand
Soon after nosotros visited Sanand in 2018, we asked Anantshree Chaturvedi a couple of questions about his views of the new greenfield plant, the new line of business and the time to come use of the site itself. His response was included in our February 2022 comprehend story.
"The aseptic liquid packaging project is yet again some other case of Uflex taking on a massive claiming and utilizing a gap that exists in the market to provide a niche solution to large set of customers who have not imagined a dissimilar way to parcel liquids in flexible packaging containers for the last 40 years. Asepto is the start of a new era of non only products, but of a business organization philosophy that will change the future of Uflex from beingness a flexible packaging and polymer science visitor to a product development and textile science company.
"The state-of-the-art production facilities of Asepto are the latest and all-time case of a philosophy that Uflex has always followed – never purchase a used automobile, when you lot can buy a new one. Also, never purchase old engineering science when a new i exists or is on the cards to be implemented and deployed in the future. This combined with our production creation philosophy is what enables Uflex to accept on aggressive and groundbreaking challenges.
"With regards to the remainder of the three-fourths of the land at Sanand, Gujarat, there are certainly many businesses within Uflex that are interested in expanding in that space. My estimate is that the near profitable businesses – holograms, chemicals, and engineering – might go the right of first refusal to go into the rest of the country. However, nothing is really off the tabular array including new ideas and concepts that Uflex is currently working on."
Source: https://packagingsouthasia.com/type-of-packaging/monocartons/asepto-in-sanand-for-liquid-food-and-beverage-packaging/
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