final project report nitin tripathi 1480

8/6/2019 Final Project Report Nitin Tripathi 1480

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(To be submitted on or before 14th May, 2010)



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AACCKKNNOOWWLLEEDDGGMMEENNTTSS

Project work is never the task of an individual. It is a combination of ideas, suggestions

and contributions. I take this opportunity to sincerely thank all those who have helped usand contributed in this initiative with their suggestions, guidance and support so that we

could culminate the assignment successfully.This project would have been a lot more difficult if I was not assisted by these people. At

the initial stage it was difficult for me to go about things because everything seemed to bequite tough and new for me but with the assistance of my company guide it became very

easy and at the same time a great learning experience.I always feel that I could not give enough time to my faculty guide because of the work

but I really appreciate the manner in which he treated me any time I went for his help andsupport. He was always eager to know and understand my project and its progress and

encouraged me to do things well and if there was any help required he was always there.It is my obligation to acknowledge and thank them for their help.

a) Mr. Jatin Khannab) Dr. Jamshed modic) Mrs. Tressa dmelo



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Authorisation ……...……………………………………………………………..….....2

Acknowledgments……………………………………………........................................3

Executive Summary/Abstract/Synopsis…………………………...........……...………..5

1. Introduction.................................................................................................................7

1.1. Packaging Types ……………………………………………………………….81.2. Packaging Machines……………………………………………….....................9

1.3 Label Dispensers and Label Applicators ……………………………………….91.4 A Cartoning Machine…………………………………………………………..12

1.5 Types of Cartons……………………………………………………………….121.6 Blister Pack ………………………………………………………………… ....13

1.7 Corrugated Fiberboard ……………………………………………………… ...141.8 The Vertical Form Fill Sealing Machine (FFS) ……………………………….14

1.9 Shrink Wrap……………………………………………………………………151.10 A Conveyor Belt (or belt conveyor)....................................................................17

1.11 Limitations of the Project …………………………………………………… ....19

1.12 Suggestions……………………………………………………………………...21

2 . Main Text……………………………………………………………………… ....22

2.1 Packaging Industries of India…………………………………………………....232.2 New Trends in Packaging Industries…………………………………………….252.3Japan - The Largest Packaging Machine Producer……………………................26

2.4 Latest Buzz and Issues of Packaging…………………………………………….28

3 Attachments ……………………………………………………………………… .30

4 References…………………………………....………….…………………..............34

5 Glossary……………………………………………………………………………35



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EEXXEECCUUTTIIVVEE SSUUMMMMAARRYY / / AABBSSTTRRAACCTT

This internship project is to educate customers about the new packaging equipments

which are available with our company and which are quite useful in increasing the

productivity of the products. To provide complete packaging solutions and all packaging

needs to our global customers, be it machinery, accessories or consumables.

Till date I have visited many companies where I got a chance to meet with the top level

corporates of some of the best companies in India. My company guide Mr. Jatin Khanna

expressed his desire to focus on the top level Pharmaceutical companies as well as the top

10 FMCG companies in India. The corporate people are not easy to contact with so a

number of phone calls have to be made to fix with an appointment. They can be from

different departments like packaging ,production ,purchase or procurement. These people

work in a group and they take a final decision for the machine only after having a fruitful

discussion with their team members and this is because the project completion with any

company takes time.

There are a number of corporate people of good companies to whom I have sent emails or

sent the hard copy of catalog through courier to have a better insight of our company and

the products we deal with. Many have come up with good responses, few are taking their

time and some don’t have any requirements at present. Our Top class reference list is the

best USP of our company which helps a lot when we represent ourself in differentcompanies that we follow. It gives me immense proud and happiness when I

communicate this reference list with other customers and feel great to be a part of such

good company.

I always try to spread the name of my company to as many companies as possible

because to have a better sale of the products the other party should be aware of the name

and brand of the company and then subsequently they feel quite acquainted and familiar

with the name to give a final order for the machine. The next page has the list of the

companies and the person to whom I have met uptill now.



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NAME OF THE COMPANY PERSON MET

AJANTA PHARMA LTD. MR. HARSHAD THAMBE

STALLEN MR. H.S. PATEL

SUN PHARMACEUTICAL LTD. MR. VIPUL KANJIA

ASIAN PAINTS MR. NAVINDER SINGH

HINDUSTAN UNILEVER LTD. MR. K V KRISHNAN

COLGATE-PALMOLIVE MR. K.M. LAXMI NARAYAN

ARISTO PHARMA MRS.MANJIRI MOGHE

PARLE PRODUCTS MR. RANJEET PATIL

VHB LIFE SCIENCES MR. NILESH MEHTA

TAJ PHARMACEUTICAL MR. ABISEKH SINGH

EMBIO LTD. MR. V PRASAD

THEMIS MEDICARE MRS. KAVITA SUVARNA

JB CHEMICALS LTD. MRS. MANALI M JADHAV

GLAXO SMITHKLINE MR. J.S. PATIL

KOPRAN LTD. MR. R.K. KAMAT

Some of the above names are still in talks at present and they may become our clients in

future.



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11.. IINNTTRROODDUUCCTTIIOONN

My project is all about sale of the packaging products The project is divided into various

phases and the phases of the projects are carried in a sequential manner so as to give aproper flow to the success of the project.

1. Ist Phase

The first phase begins with preparing of a customer database categorized in different

sectors (eg. Pharmaceutical or FMCG) and then doing a study of the products that the

company is dealing with so that we could focus more on that particular product while

carrying out the discussion with them. Then try to contact the concerned person dealing

with the machinery. I further try to arrange for a meeting and discuss more about the

company and products we are dealing with.

2. IInd Phase

The second phase begins with the follow ups of the customers contacted before and try to

know if there is any further requirements of the products. It is a bit easier to approach in

this phase because our companies profile and product line is clear in the minds of the

customers at this stage and they are quite familier with the companies name and it’s

current clients.

3.IIIrd Phase

This is the phase where we actually fulfill the customers requirement of any machine. We

send them proper quotation for the machine and then help in installing the machine at

their desired location.



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PPaacckkaaggiinngg TTyyppeess

Packaging may be looked at as being of several different types. For example a transport

package or distribution package can be the shipping container used to ship, store, andhandle the product or inner packages. Some identify a consumer package as one which is

directed toward a consumer or household.

Packaging may be described in relation to the type of product being packaged: medical

device packaging, bulk chemical packaging, over-the-counter drug packaging,

retail food packaging, military materiel packaging, pharmaceutical packaging, etc.

It is sometimes convenient to categorize packages by layer or function: "primary",

"secondary", etc.

Primary packaging is the material that first envelops the product and holds it. This

usually is the smallest unit of distribution or use and is the package which is in direct

contact with the contents.

Secondary packaging is outside the primary packaging, perhaps used to group primary

packages together.

Tertiary packaging is used for bulk handling, warehouse storage and transport shipping.

The most common form is a palletized unit load that packs tightly into containers.

These broad categories can be somewhat arbitrary. For example, depending on the use,

a shrink wrap can be primary packaging when applied directly to the product, secondary

packaging when combining smaller packages, and tertiary packaging on some

distribution packs.



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PPaacckkaaggiinngg MMaacchhiinneess

A choice of packaging machinery includes: technical capabilities, labor requirements,

worker safety, maintainability, serviceability, reliability, ability to integrate into the

packaging line, capital cost, floorspace, flexibility (change-over, materials, etc.), energy

usage, quality of outgoing packages, qualifications (for food, pharmaceuticals, etc.),

throughput, efficiency, productivity, ergonomics, return on investment, etc.

Packaging machines may be of the following general types:

Blister packs, skin packs and Vacuum Packaging Machines

Bottle caps equipment, Over-Capping, Lidding, Closing, Seaming and Sealing

Machines Box, Case and Tray Forming, Packing, Unpacking, Closing and Sealing Machines

Cartoning machines

Cleaning, Sterilizing, Cooling and Drying Machines

Converting Machines

Conveyor belts, Accumulating and Related Machines

Feeding, Orienting, Placing and Related Machines

Filling Machines: handling liquid and powdered products

Inspecting, Detecting and Check weigher Machines Label dispensers Help peel and apply labels more efficiently

Package Filling and Closing Machines

Palletizing, Depalletizing, Unit load assembly

Product Identification: labeling, marking, etc.

Shrink wrap Machines

Form, Fill and Seal Machines

Other speciality machinery: slitters, perforating, laser cutters, parts attachment, etc.

Label Dispensers and Label Applicators

These machines are built to simplify the process of removing a label from its liner or

backing tape. Some are bench-top for dispensing the labels while others include the

application of the label to the item (such as a package).Label dispensers are designed



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with varying sizes and features which are often specific to the type of label they can

dispense and to the degree of automation desired.

The labels are applied by either manual application or automatic application. Automatic

application are basically of two types, tamp on or wipe on.

Label dispensers have many uses. Imagine how many items you purchase have labels,

almost everything. Those labels were either applied by a machine or by hand, and most

likely were peeled from the backing paper using some sort of label dispenser. Some of

the more popular are bulk mailing, manufacturing, packaging, food and beverage, fast

food, photo labs, and more.

Patents on Manual label dispensers go back to the 1920s. They are designed for light-

duty use. They are operated by hand and are not automated, but still assist in the process

of removing labels from their liners. Many manual label dispensers can dispense multiplerolls at once. Operation is performed by pulling the liner/backing paper around a plate or

bar which causes the label to peel away from the backing paper. This happens because

the backing paper is usually thinner than the label itself and is also underneath. When the

liner is forced around a tight radius the label lifts away and protrudes through the front or

top of the dispenser.

Electric Semi-automatic label dispensers were first patented in the early 1970s. They

were originally designed for multiple-row address labels for bulk mailing houses. On

average a good mailing house employee could apply approximately 500 labels per hour

to envelopes. The label dispenser increased this to over 2,000 per hour. These dispensers

advance individual or multiple-row labels and remove them from their lining similar to a

manual dispenser, but instead of manually pulling on the liner, label advancement occurs

when a trigger on the dispenser detects the absence of a label, such as when the operator

removes the label. The sensor then closes the circuit and engages the motor, dispensing

the next label until the sensor once again detects the label which opens the circuit. The

first electric dispenser was designed with the limit switch on the left of a 16" wide

machine. 4-up multiple-row labels were loaded into the machine and once activated

would advance one row of labels. The operator would take the labels from right to left, so

that when the leftmost label was taken, the next row advanced, automatically providing a

constant supply of labels to apply. The labels are also peeled without the natural curl that

will happen when pulled from the backing paper with fingers. Also, only one hand was

needed to take the label, the other hand could be used to move the material the label was

being applied to.



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Semi-automatic label dispensers are often built to withstand industrial conditions

Motor: The motor automates the label dispenser and controls the speed at which

labels are dispensed.

Feed-Roller: This actually is the first patented method used in the semi-automatic

label dispenser to advance the label forward. The label material is fed over the

peeling edge, then through a feed-roller assembly which pinches the label material

between a metal roller and a rubber roller. The metal roller is held in place with

bushings pressed into aluminum blocks which hinge on a rod supported between two

sideframes. The blocks use springs on each side to hold tension against the rubber

roller (driven by a motor), and this also holds the tracking of the label material to the

side of the machine with the sensor. Using this method label stock up to 16" width

can be advanced and tracked perfectly. The disadvantage/advantage to this method is

waste is not collected, but pushed out through the rear of the machine where it can be

fed into a trash receptacle.

Take-up hub/spool: This can take the place of the feed-roller. The take-up hub

consists of a bar and a liner holder/clip, which are connected to the motor on a single

side-frame. In operation, they turn in sync with the motor and wind the label liner in

order to collect it in one place. As the take-up hub turns, pressure is placed in the liner

and it is stretched across the strip plate, where peeling, or separation, occurs.

Strip plate: A component of the machine which acts as a separator for the label and itsliner. Each label is pulled across the strip plate until it is recognized by a photo sensor

or limit switch. Strip plates can be of varying design and material, but they are often

made of plastic, metal coil, or aluminum.

Photo detector or Limit switch: Used to trigger label advancement. Every semi-

automatic label dispenser is equipped with one or the other. These detect the absence

or presence of a label to facilitate dispensing.

Limit switch: This is the original method of label detection and can be used for most

applications, it can detect a wide variety of labels.

Photo detector / Electric eye: Is an alternate method which uses a beam of light

broken by the label as it passes over/between the sensors. It can be used for many

different label types, but transparent material is an issue.



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A Cartoning Machine

It is a packaging machine that forms cartons: erect, close, folded, side seamed and sealed

cartons.Packaging machines which form a carton board blank into a carton filled with a

product or bag of products or number of products say into single carton, after the

filling,the machine engages its tabs / slots to apply adhesive and close both the ends of

carton completely sealing the carton.

Cartoning machines can be divided into two types:

Horizontal Cartoning Machine

Vertical Cartoning Machine

A cartoning machine which picks a single piece from stack of folded carton and erects it,

fills with a product or bag of products or number of products horizontally through an

open end and closes by tucking the end flaps of the carton or applying glue or adhesive.

The product might be push in the carton either through the mechanical sleeve or

by pressurized air. This type of Cartoning machine is widely used for

packaging foodstuffs, confectionery, medicine, cosmetics, sundry goods, etc.A cartoning

machine which erects a folded carton, fills with a product or number of products

vertically through an open end and closes by either tucking the end flaps of the carton or

applying glue or adhesive, is called a top end cartoning machine. Widely used for

packaging bottled foodstuffs, confectionery, medicine, cosmetics, etc.

Types of Cartons

Folding Cartons

A carton is a type of packaging suitable for food, pharmaceuticals, hardware, and many

other types of products.

Folding cartons are usually combined into a tube at the manufacturer and shipped flat

(knocked down) to the packager.

Tray styles have a solid bottom and are often shipped as flat blanks and assembled by the

packager. Some also are self-erecting.

High speed equipment is available to set-up, load, and close the cartons.



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Egg Carton

Egg cartons or trays are designed to protect whole eggs while in transit.

Traditionally these have been made of molded pulp. This uses recycled newsprint which

is molded into a shape which protects the eggs.

More recently egg cartons have also be made from expanded polystyrene (similar

to Styrofoam) and PET.

Aseptic Carton

Cartons for liquids can be fabricated from laminates of paperboard, foil, and

polyethylene. Most are based on either Tetra Pak or Combibloc systems.

One option is to have the printed laminate supplied on a roll. The carton is cut, scorred,

and formed at the packager.

A second option is to have the pre-assembled tubes delivered to the packager for

completion and filling.

These are suited for aseptic processing and are used for milk, soup, juice, etc.

Gable Top

Gable top cartons are often used for liquid products such as milk, juice, etc. These used

polyethylene-coated paperboard and sometimes a foil laminate.

Most are opened by pushing open the gables at the top. Some have fitments to assist in

opening and pouring the contents.

Blister Pack

It is a term for several types of pre-formed plastic packaging used for small

consumer goods. The two primary components of a blister pack are the cavity or pocket

made from a "formable" web, either plastic or aluminium - and the lidding, made from

paper, carton, plastic or aluminium. The "formed" cavity or pocket contains the product

and the "lidding" seals the product in the package. Blister packs are created by means of a

form-fill-seal process at the pharmaceutical company or designated contract packer. A

form-fill-seal process means that the blister pack is created from rolls of flat sheet or film,

filled with the pharmaceutical product and closed (sealed) on the same equipment. Such

equipment is called a blisterline.Blister packs consist of two principal components : 1) a



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formed base web creating the cavity inside which the product fits and 2) the lidding foil

for dispensing the product out of the pack. There are two types of forming the cavity into

a base web sheet: thermoforming and cold forming.

Corrugated Fiberboard

It is a paper-based material consisting of a fluted corrugated sheet and one or two flat

linerboards. It is widely used in the manufacture of corrugated boxes and shipping

containers.The corrugated medium and linerboard are made of containerboard, a paper-

like material usually over ten mils (0.010 inch, or 0.25 mm) thick. Paperboard and

corrugated fiberboard are sometimes called cardboard, although cardboard might be any

heavy paper-pulp based board.

The Vertical Form Fill Sealing Machine (FFS)

It is a type of automated assembly-line product packaging system, commonly used to in

the packaging industry for food, and a wide variety of other products. The machine

constructs plastic bags out of a flat roll of plastic film, while simultaneously filling the

bags with product and sealing the filled bags. Both solids and liquids can be bagged using

this packaging system.The typical machine is loaded with a continuous flat roll of plastic

film, which has had labeling and artwork applied to the exterior or interior of the film.

Note that while plastic is the most commonly used packaging material in the food

industry, the technology can also be used to form continuous paper and fabric product

containers by changing the edge sealing/seaming methods.For some products the film

may first be fed through a sterilizing chemical bath and dryer prior to use in the

packaging system.The film approaches the back of a long hollow conical tube, and when

the center of the plastic is near the tube, the outer edges of the film form flaps that wrap

around the conical tube. The film is pulled downward around the outside of the tube and

a vertical heat-sealing bar clamps onto the edges of the film, bonding the film by melting

the seam edges together.To start the bagging process, a horizontal sealing bar clampsacross the bottom edge of the tube, bonding the film together, and cutting off any film

below. The sealed tube end is then lowered onto a precision weighing table and the

product to be bagged is dispensed through the long conical tube in the center of the

bag.When the tare weight of the product-filled bag is reached, filling stops, and the

horizontal sealing bar seals the top of the bag, and simulatenously forms the bottom of



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the next bag above. This bag is then cut off from the tube and is now a sealed package,

ready to advance onward into the product boxing and shipping processes.

During the final sealing process, the bag may be filled with air from a blower or from

an inert gas supply. Inflating the bag helps reduce the crushing of fragile products such

as potato chips, while inflating with an inert gas helps drive out oxygen and retards the

growth of bacteria that would spoil the product.Dual web systems are also available for

four side sealed pouches, as well as pouches requiring different materials for each side.

Dual web systems use two rolls of material instead of one, which are fed in from opposite

sides of the machine. The bottom and sides are heat sealed together to form the pouch,

and the product is loaded from the top. The pouch with loaded product then advances

downwards and the top is sealed and pouch is cut off. The sealing of the top of the pouch

forms the bottom of the next pouch. During this process a tear notch may be added.The

feeding of material and cutting of the pouch can be determined either by pouch length, orindexing to an eyespot, which is detected by a visual sensor.While single web systems are

popular for food applications, the dual web four side seal system is often popular for IVD

and Medical device products.Closely related is the horizontal form-fill-seal machine,

which is generally uses more floor space than a vertical system.Modern advancements in

pouch forming technology have allowed for smaller and smaller Vertical pouch forming

systems.

Shrink Wrap

Shrink wrap, also shrinkwrap or shrink film, is a material made up of polymer plastic

film. When heat is applied to this material it shrinks tightly over whatever it is covering.

Heat can be applied with a hand held heat gun (electric or gas) or the product and film

can pass through a heat tunnel on a conveyor.

Shrink wrap is commonly used as an overwrap on many types of packaging,

including cartons, boxes, beverage cans and pallet loads. A variety of products may be

enclosed in shrink wrap to stabilize the products, unitize them, keep them clean, add a

degree of tamper resistance, etc. It can be the primary covering for some foods such as

cheese and meats. It is also used to cover boats after manufacture and for winter

storage. Heat-shrink tubing is used to seal electric wiring.

Shrink bands are applied over parts of packages for tamper resistance or labels. It can

also combine two packages or parts.



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The most commonly used shrink wrap is polyolefin. It is available in a variety of

thicknesses, clarities, strengths and shrink ratios. The two primary films are either

crosslinked, or non crosslinked. Other shrink films include PVC and several other

compositions.

Coextrusions and laminations are available for specific mechanical and barrier properties

for shrink wrapping food.

Current trends are to improve film properties which may lead to reduced caliper (source

reduction) and to improve process efficiency (cost and energy savings).

A shrink film can be made to shrink in one direction (unidirectional or mono-directional)

or in both directions (bidirectional).

Films are stretched when they are warm to orient the molecules from their initial random

pattern. Cooling the film sets the film's characteristics until it is reheated: this causes it toshrink back toward its initial dimensions.

Prior to orientation, the molecules of a sheet or tube are randomly intertwined like a bowl

of spaghetti. The molecules are coiled and twisted and have no particular alignment.

However when a draw force is imposed, the amorphous regions of the chains are

straightened and aligned to the direction of orientation. By applying proper cooling, the

molecules will be frozen in this state until sufficient heat energy is applied to allow the

chains to shrink back. One can visualize this phenomenon by stretching a rubber band

and dipping it into liquid nitrogen so as to freeze in the stretched state. The band willremain in this state as long as it is kept at sufficiently cold temperatures. However, when

enough heat energy is applied, the rubber band will shrink back to its original relaxed

state. Orientation on a commercial scale can be achieved using either of two processes: a

tenterframe or a bubble process. Tenterframe technology is used to produce a variety of

―heat-set‖ products, with BOPP being the most common (Heat-setting is a process

whereby a film is reheated in a constrained state such that the shrink properties are

destroyed). The second commercial process is the bubble process, sometimes referred to

as the tubular process. In this process, a primary tube is produced by either blowing or

casting the tube onto an external or internal mandrel, respectively. It is common to use

water to help cool the primary tube at this point. After the primary tube has been cooled,

it is then reheated and inflated into a second bubble using air much like a balloon is

blown. Upon inflation, the tube is oriented in both directions simultaneously. The family

of shrink films has broadened over the years with many multilayer constructions being

sold today. The key attributes which are important to shrink films include shrink,



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sealability, optics, toughness, and slip. Each of these attributes is composed of several

facets. With regard to shrink properties, there are onset temperature, free shrink, shrink

force, shrink temperature range, memory, and overall package appearance. Each of these

facets must be considered when choosing an appropriate shrink wrap for a particular

application

Shrink wrap is applied over or around the intended item, often by automated equipment.

It is then sent through a heat tunnel or oven for shrinking. Heat guns are also used for

large items.

Shrink wrap can be supplied in several forms. Flat rollstock can be wrapped around a

product but centerfolded film is by far the most popular, supplied on a roll the plastic is

folded in half: product is placed in the center portion, the remaining three edges are

sealed to form a bag, and the package then heated which causes the bag to shrink and

conform to the product placed in the bag. Less popular are the pre-formed Shrink

bags plastic bags with one end open: the product is placed in the bag, sealed, and sent for

heat shrinking.

Shrink wrap can be used to wrap buildings. It is far superior to blue tarps for wrapping

roofs after hurricanes, earthquakes, tornadoes and other disasters. Shrink wrap can be

used for environmental containments to facilitate safe removal of asbestos, lead and other

hazards.

Shrink wrap is sometimes used to wrap up books. Software on carriers such as CDs or

DVDs are often sold in boxes that are packaged in shrink wrap. The licenses of such

software are typically put inside the boxes, making it impossible to read them before

purchasing. This has raised questions about the validity of such shrink wrap licenses.

A Conveyor Belt (or Belt Conveyor)

It consists of two or more pulleys, with a continuous loop of material - the conveyor belt -

that rotates about them. One or both of the pulleys are powered, moving the belt and the

material on the belt forward. The powered pulley is called the drive pulley while the

unpowered pulley is called the idler. There are two main industrial classes of belt

conveyors; Those in general material handling such as those moving boxes along inside a

factory and bulk material handling such as those used to transport industrial and

agricultural materials, such as grain, coal, ores, etc. generally in outdoor locations.

Conveyors are used as components in automated distribution and warehousing. In



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combination with computer controlled pallet handling equipment this allows for more

efficient retail, wholesale, and manufacturing distribution. It is considered a labor saving

system that allows large volumes to move rapidly through a process, allowing companies

to ship or receive higher volumes with smaller storage space and with less labor expense.



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LLIIMMIITTAATTIIOONNSS OOFF TTHHEE PPRROOJJEECCTT

i) The Secondary Data collected are many times wrong

The database which is collected by us comprising the company location and completemailing address is many times not correct, especially the phone no’s which keep onchanging so we have to make a number of calls to get the correct number.

ii) Error in contacting the concerned person

Many times it happen that we go on in discussion with a wrong person who is not directlyconcerned with the packaging machines and it results in the wastage of time and no result

comes out at the end. In some cases the contacted person hides the details of the concernedperson thinking it to be of lesser importance to them .

iii) Delay in actions taken by both the parties

In many cases it happens that the contacted customer takes too much time in ending theproject and simply delay in their actions which badly affect the progress of the project. In

other cases it can be from our part also where we delay in understanding the exactneeds of the customer and also delay in sending them the exact quotation.

iv) Customers think Foreign companies fail to give better servicing

I have realized that many of the customers have in their minds that the foreign companiesare not able to provide with the best of the servicing and this is because they switch to

other local companies

v) Customer hiding the exact details of the product

Many times it happens that the customer is in a hurry to get the quotation as soon as

possible for having a general idea and for this he hides certain important details which arevery important to get the correct quotation as well as correct price.

vi) Price focused customers

During my project work I have rea lized that most of the customers are mainly focused on

prices and they simply don’t try to understand on the functionality part of the machine and

they end up taking an cheaper machine with low functionality .



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vii) Lack of competitor analysis

There is a lack of analysis to be done regarding our competitors database , which all

products they are dealing with and a perfect table match with the prices that they are

quoting for the same machine. This can help us in matching up with the price level of other companies along with maintaining a good quality and servicing.

viii) Lack of Marketing and Branding exercise

There should be a much more emphasis on the marketing of the company name and the

products so that the name of the company stays in the mind of the customer to have dealfurther .I have basically tried to work on this aspect.

ix) Come up with some promotional strategy

Here we can come up with some kind of materials which could be handed over to the

contacted person at the time of meetings. In this case for example we can provide a penwith a name of M&C Packaging at the time of meetings so that they can have the brand

recall in future.



21

SSUUGGGGEESSTTIIOONNSS

The Secondary Data collected are many times wrong

Actually this problem is not easy because the non-official as well as the official

company websites from where we pick these data are not updated many times so

we land up getting wrong data but yes we can minimize these errors by using new

edition magazines and directories related to pharmaceutical and food industries as

we are doing presently.

Lack of Marketing and Branding exercise

We can improve on our company website because many people can be impressedonly by looking to a decent and standard website where customers can see all the

product line and have an option to order the products online by submitting all the

details and specifications of the machine on the website column. This is the best way

to get a competitive advantage over some other players. we can also show our year

wise performance of the company and sales targets achieved in that particular year

along with an upward going graph. Only if the customer hits the company website

once he should not be requiring anything else. It should be of that class that we

should only try to focus our website everywhere and no need to do anything extra.

Come up with some promotional strategy

I am listing some good ones as follows , some of them can be taken up

A transparent globe with a name of M&C Packaging written inside seen from all

around the globe can be handed over to corporate people .

A transparent paper stopper in a cubical shape with the name of M&C Packaging

flashing from inside in a radium can also be handed over .

A brown tape with M&C Packaging written on it which can be used on cartons can

also be handed over to the people

A beautiful small table stand calendar can be also be given to people with the name

of M&C Packaging

A catalog book with the cover of M&C Packaging all side.



22

22.. MM A A IINN T TEEXX T T

IInn tthhiiss sseeccttiioonn II wwoouulldd lliik k ee ttoo ddiissccuussss tthhee mmaaiinn bbuussiinneessss oof f tthhee rreeppoorrtt.. TThhee mmaaiinn f f uunnccttiioonn

oof f tthhiiss ppaarrtt iiss ttoo pprreesseenntt ddaattaa iinn aann oorrggaanniizzeedd f f oorrmm aanndd ddiissccuussss tthhee f f llooww oof f ddaattaa ..

TThhee aabboovvee ddiiaaggrraamm sshhoowwss aa f f llooww ddiiaaggrraamm hhooww wwee pprroocceeeedd tthhrroouugghh oouurr pprroo j jeecctt.. TThhiiss

sseerriieess oof f sstteeppss iiss tthhee bbaassiicc sstteeppss wwhhiicchh wwee f f oollllooww f f oorr aannyy nneeww ttyyppee oof f ccuussttoommeerr hhaannddlliinngg..

1• Fetch the list of new customers.

2

• Try to contact the concerned person related to the packaging

machines.

3• Share our company profile and undergoing business.

4• If possible arrange for a meeting to discuss more on it.

5

•

Know the specific needs of the customer and try to presentthe suitable model of machine customized to his needs.



23

PPAACCKKAAGGIINNGG IINNDDUUSSTTRRIIEESS OOFF IINNDDIIAA

Packaging is among the high growth industries in India. A high degree of potential exists

for almost all user segments which are expanding appreciably-Processessed foods, hardand soft drinks, fruit and marine products, cosmetics and personalcare, office stationary

and accessories, fabrics and garments, white goods and other durables, electrical

appliances and equipments, entertainment and other electronics, shoes and leather ware,

gems and jewellery, toys and sports goods, chemicals and fertilizers. Due to lower

manufacturing costs, India is fast becoming a preferred hub for packaging production.

The Indian packaging industry has made a mark with its exports that comprise flattened

cans, printed sheets and components, crown cork, lug caps, plastic film laminates, craft

paper, paper board and packaging machinery, while the imports include tinplate, coating

and lining compounds and others. In India, the fastest growing packaging segments are

laminates and flexible packaging, especially PET and woven sacks.

The market size for packaging materials & systems for food, pharmaceuticals, cosmetics,

toiletries, Ind. products, textiles, handicrafts, etc. accounts for 4%, while rigid & semi-

rigid plastic containers is about 9%.The metal and tin containers accounts for 10%, glass

containers 10% , corrugated board & boxes 23%, paper & paper board 36% and other

ancillary materials like tapes straps, labels, adhesives, etc. - 8%.

Upgradation, both of functionality and aesthetics, characterizes the recent trends in the

industry. Elaborate and more expensive packaging is penetrating deeper into marketing of

industrial products and even agro-based products, like food and personalcare products,

drugs and pharmaceuticals, consumer durables and electronic products, especially

entertainment products.

Packaging market size in India is about Rs 65,000 crore is growing at the rate of 15 per

cent per annum. Currently rigid packaging enjoys more than 65% market share but the

traditional rigid packaging users are migrating to flexible packaging in a big way.Market

size of PET/BOPP and other flexible film-based manufacturing segment is estimated at

around Rs 25 billion. The cost impact of PET film and BOPP film on the overall

packaging cost ranges from 35-85% depending on the product to be packaged. The main

players are Paper Products, Akar Group, Orient Press, India Foils, RT Packaging and

Mukund Flex Pack. Akar Group consists of Akar Laminations, Sharp Industries andVishnu Vijay Packagers. The overall growth rate of the industry has tapered off to around

9%. The flexible packaging industry is expected to grow at about 10-15% per annum in

the coming years. The laminated products are growing at around 30% p.a. There are

about 600-700 packaging machinery manufacturers, 95% of which are in the small and

medium sector located all over India.



24

The top packaging companies of India includes Parksons Packaging System , ITC

Limited , Hindalco , Tata Tinplate Company of India , Moldtek Technologies Limited ,

Gujarat Glass Ltd , Advance Packaging , AMAC Plastic Packaging, E C Packaging Pvt.

Ltd, The Paper Products Limited.etc.

The large and fast growing Indian middle class population and the growth of organizedretail sector are the catalysts to growth in packaging. Packaging of essential products like

food, beverage, milk, vegetable, food grains and pharma are the key driving segments

because of the huge domestic consumption.



25

NNEEWW TTRREENNDDSS IINN PPAACCKKAAGGIINNGG IINNDDUUSSTTRRIIEESS

The new trends and development are essential to the industry’s bright future, the Indian

Institute of Packaging, through the packaging companies, seeks to provide a perfect

platform to bring the packaging industry under one roof. With this the industry has

opportunity to connect at this highly specialized event where the issues of meeting the

soaring demand for more sophisticated packaging together with the ever present need for

increased productivity are addressed.

Indian Packaging industry with a growth of more than 15% p.a. accounts for USD 14

Billion. This shows the immense potential in the industry. This growth is expected to be

doubled in next two years and figures indicate towards a change in the industrial and

consumer set up. Packaging today, has grown in importance and is regarded as vital

marketing tool. It enhances product value and helps expand market within and outside

country. The packaging industry can be characterized as global and fast growing industry.

With a rapid growth in markets like Food, beverage, pharmaceutical, cosmetics and

textile has provided momentum for the need of packaging as all these sectors need

specialized packaging. Availability of most of the raw material in abundance that is

required in packaging industry such as paper, plastic, board, glass, metal adds to the

further growth of industry.

International FoodTec 2010 - International exhibition on food processing & packaging

technology, equipments and supplies. At the same time the other concurrent events viz. a

high level International Packaging Conference & the National Awards for Excellence in

Packaging will be organized by Indian Institute of Packaging.



26

JJAAPPAANN – – TTHHEE LLAARRGGEESSTT PPAACCKKAAGGIINNGG MMAACCHHIINNEE PPRROODDUUCCEERR

Japanese packaging equipment made its first appearance in the 1910s when bottling

machines for beer and canning machines for fish and meat were developed. But

subsequent wars prevented manufacturers from developing other types of packaging

equipment. It was 30 years later in 1947 when a caramel packaging machine was

developed that the packaging machinery industry was beginning to take shape in Japan

In the 1950s, various kinds of packaging equipment were developed including cigarette

packaging machines, powder food and medicine pouch packaging machines, bagging

machines for, among others, instant noodles, vacuum packaging machines, cartoning

machines, tying machines and paper strapping machines. Packaging equipment continued

to be developed in a wide variety in the following years. It may be said that the industry

had built up its foundation in the 1960s. Japanese packaging machinery industry came to

be known both at home and abroad during this period.

Supermarkets made their debut in the mid-1960s and spread throughout the nation.

Consumer goods including foodstuffs were sold in a "self-service" method in these

stores, making it necessary to prepack them so that a customer can take them to a cashier

by himself. Demand for packaging equipment soared as a result. Since, however,packaging machinery manufacturers hadn't have enough experience to satisfy all the

requirements of end users, they positively tied up with the U.S and European

manufacturers to raise their technical standards.

The first oil crisis that hit the world's economy in 1973 forced Japan to enter a slow

growth era, and a mass production method so far dominant in consumer good

manufacturing gave way to a diversified small-quantity production method. In addition,

consumers' needs became more diversified. As a result, the end users' demand for

packaging equipment came to be focused on versatile machines capable of multiple types

of packaging and also on the equipment manufactured according to their own

specifications. The equipment made in technical cooperation with foreign manufacturers

could no longer satisfy the needs of Japanese end users, and efforts to develop equipment

capable of meeting their needs began in full swing. It was in the 1970s that Japan laid the



27

foundations for the present packaging machinery technologies. Representative among

them are technologies for adopting microcomputer control to packaging equipment and a

heat pipe to heat sealing devices.

Japan is now one of the largest packaging machinery producers in the world. Her

production, exports and imports of the equipment are as provided below.



28

LLAATTEESSTT BBUUZZZZ AANNDD IISSSSUUEESS OOFF PPAACCKKAAGGIINNGG

Second-tier cities become centre of packaging activity The rise in organized retailing in India’s second-tier cities made for a competitive

packaging market in 2008. Companies like Hindustan Unilever Ltd, Procter & GambleIndia Ltd, Nestlé India Ltd, ITC Ltd, Coca-Cola India Ltd, PepsiCo India Ltd and Dabur

India Ltd became very aggressive during the review period, and packaging became a bigtool for launching new, India-specific products in different shapes and sizes. The review

period witnessed a flux of partnerships and joint ventures, with many foreign packagingplayers entering the scene to gain a slice of the large pie. Alcan Packaging- part of Rio

Tinto Alcan, Klockner Pentaplast Group (KP) - a German-based packaging solutionsprovider, Polish firm Can Pak and Bosch Packaging either announced new investments or

disclosed plans for the expansion of their existing investments during the review period.

Environmental concerns continue to hamper polymer-based packaging growth

Environmental concerns are fast catching the attention of all the stake holders in the

Indian packaging industry. The expansion of packaging as a profitable industry in India,dragged along by that of the retail and FMCG sectors, has brought with it environmental

concerns. Organizations such as the Indian Centre for Plastics in the Environment wereactively seen promoting awareness in this regard in order to promote the packaging

industry and make people aware of the real concerns about the environment. The centre isthe accredited body of The Ministry of Environment and Forests (MOEF) and undertook

continuous awareness programs by publishing information on waste management

materials, statistics, as well as going in to school and colleges and teaching people aboutthe correct usage of polymer. Corporations were also seen to be making efforts to adaptgreener technologies.

Cost advantages make India a preferred packaging export hub

Due to lower manufacturing costs, India is fast becoming a preferred hub for packagingproduction. The Indian packaging industry has made a mark with its exports that

comprise flattened cans, printed sheets and components, crown cork, lug caps, plasticfilm laminates, craft paper, paper board and packaging machinery, while the imports

include tinplate, lacquers, coating and lining compounds. In India, the fastest growing

packaging segments are laminates and flexible packaging, especially PET and wovensacks. On the global scene ruled by the World Trade Organization, it is imperative forIndia to upgrade its packaging standards through innovative technologies in order to be

on a par with the world’s best practice. Packaging labels must inform consumers aboutthe ingredients of the product, the nutritional value, and the manufacturing and expiry

dates of the products; something which is being made mandatory by the government.Almost all the major players were seen to expand their existing capabilities to tap into the

fast growing export market for Indian packaging products.



29

Inflation and high oil prices eating in to the margins of packaging companies

Many flexible and paper-based packaging manufacturers experienced difficulties relatingto the rise in the cost of paper as well as high oil prices during the first half of 2008. The

rising costs of paper reduced the margins of industry players. The Indian governmentannounced a cut in the excise duty imposed on the finished goods from 12% to 8% in

2008, yet this was not sufficient saving for the industry that was badly reeling from thehigh production costs. The government, in the budget, reduced the excise duty on paper

mills from 12% to 8%, which the paper manufacturers did not pass on to the customers.High oil prices during the first half of the year affected the businesses of polymer-based

packaging providers who also found it tough to survive in the market



30

33.. AATTTTAACCHHMMEENNTTSS

HHeerree II wwoouulldd lliik k ee ttoo iinncclluuddee oonnee ccaassee ssttuuddyy oof f aa PPaacck k aaggiinngg mmaacchhiinnee ccoommppaannyy..

Microsoft Business Solutions

Matrix Packaging Machinery

THE COMPANY

Founded in 1988, Matrix Packaging Machinery is one of the world's leadingmanufacturers of vertical form-fill-seal packaging equipment for various manufacturing

industries. Based in Saukville, Wisconsin, Matrix serves clients worldwide.

THE BOTTOM LINE

Matrix Packaging Machinery had already deployed Microsoft Business SolutionsSolomon when it realized it needed to monitor its inventory and work in progress.

Adding a work order module produced an incremental ROI by greatly speeding ordertimes, supporting better inventory management, enabling more accurate and timely

financial projections, and reducing financial personnel costs.

THE CHALLENGE

In the late 1990s and early 2000s, Matrix was growing but faced several major

challenges:

Matrix was keeping track of thousands of parts on paper and had no way of knowing

which parts were available and which needed to be ordered for the next production run.

Without real-time knowledge of inventory levels and work in progress (WIP), Matrix

could not close its books in a timely manner.



31

To gauge the past year’s profitability, the company had to conduct a complete physical

inventory at the end of each year.

In a slow-growth industry resistant to technological change, Matrix’s managers realized

that in order to increase efficiency and profitability, the company would need a system to

monitor parts inventory levels and WIP.

THE STRATEGY

Matrix had deployed Microsoft Solomon ERP system in 1996 to support general

corporate finance and accounting. In early 2001, Microsoft offered Matrix the

opportunity to beta test a new work order management module for Matrix’s existing

Microsoft Solomon ERP system. Matrix’s managers decided to consider the opportunity,

realizing that because the software would tightly integrate with the accounting system in

use since 1996, it could simultaneously solve both their inventory management and

general ledger problems.

Matrix conducted a beta test of the system, and decided to implement the work order

module because of the following reasons:

Once Matrix’s entire parts inventory was entered into the system, the company

would no longer need to rely on a pen and paper process to keep track of parts onhand and parts orders.

With the inventory and bill of materials (BOM) software in place, Matrix could

create a real-time WIP system to track parts inventory levels as the manufacturing

line was running and as orders came in, giving the company a far more accurate

timetable for potential customers.

The work order software was customizable out of the box, with a minimum of

outside consulting work.

With these benefits in mind, Matrix’s managers decided to purchase the work order

module after the beta test was completed. The installation required a consultant and an IT

employee working for one week and one week of training for one staff member.



32

KEY BENEFIT AREAS

The deployment of the work order module quickly helped Matrix increase efficiency and

visibility into its inventory, WIP, and finances. The greatest bottom-line returns were

realized in the following areas:

Increased sales. With real-time knowledge of its parts inventory and WIP, Matrix

was able to reduce its order lead time to 10 – 12 weeks. In fact, Matrix was able to

complete some orders in a previously unheard-of three to four weeks. Because of

its new ability to promise — and deliver — rapid order times, Matrix estimates

that in the first year after the deployment, the company closed an additional 8 to

10 orders that would not have previously been possible. Matrix also enjoys far

higher manufacturing productivity and sales per employee than its nearestcompetitor.

Reduced personnel costs. Without the real-time financial information provided by

the integrated accounting and inventory system, Matrix would have to hire one

additional FTE to conduct financial analysis and other accounting tasks.

Matrix’s managers attribute the company’s ability to run a leaner, more efficient

operation directly to the Microsoft Solomon software and the work order module. Having

only 35 employees and working in a mature industry, Matrix continues to enjoy a nearly

30 percent annual growth rate due almost entirely to its ability to deliver custom-

engineered machines in a fraction of the time that it takes its competitors.

KEY COST AREAS

Key costs included personnel, hardware, software, and consulting. Personnel made up the

largest cost category, accounting for 78 percent of total project costs. This number is due

mostly to the half of an FTE needed to enter inventory data into the system on an ongoing

basis. Other cost areas included the initial one-week consulting engagement with a

Microsoft developer, the license fee for the software, and a one-time hardware cost for

servers and desktop PCs.



33

LESSONS LEARNED

Matrix reports that the deployment of the Microsoft Solomon work order management

system was nearly flawless. Matrix’s IT staff took advantage of Solomon’s customization

manager and conducted much of the custom coding in-house without hiring consultants.

Matrix attributes much of its success to its prior years of experience with the Solomon

accounting software, though Matrix’s managers suggest that if the order management

module had been available when the company originally installed Solomon in 1996, they

most likely would have implemented it then. In fact, according to Matrix’s managers, the

most significant lesson learned was that the company should have installed such a system

far sooner.

CALCULATING THE ROI

Nucleus quantified the costs of software, hardware, consulting, personnel, training, and

other investments over a 3-year period to quantify Matrix’s total investment in the work

order management software. Although the Solomon ERP system is necessary to support

the work order module, the costs of deploying Solomon at Matrix were not included in

the calculations because the deployment occurred many years earlier and was not driven

by the project. Companies not already using the Microsoft Solomon ERP system and

considering the ROI from the work order management module should include the costs of

both Solomon and the work order management module in their evaluation. Direct

benefits calculated in this report include profits from increased sales attributed to

production line efficiencies that were a direct result of the work order system.



34

44.. RREEFFEERREENNCCEESS

INDIAN PHARMA REFERENCE GUIDE , 2010. Mumbai : Kong Posh Publications

Pvt. Ltd.

PROCESSED FOODS AND BEVERAGES DIRECTORY 6 th edition , 2010 . Mumbai :

Vinayak Ingredients Pvt. Ltd.

INFOMEDIA YELLOW PAGES BUSINESS , 2009-2010 Mumbai ,Infomedia 18



35

55.. GGLLOOSSSS A A R R Y Y

In the glossary section I would like to include some of the technical words used in the

project and their explanations

i) PURCHASE ORDER

A purchase order (PO) is a commercial document issued by a buyer to a seller,indicating types, quantities, and agreed prices for products or services the

seller will provide to the buyer. Sending a PO to a supplier constitutes a legaloffer to buy products or services. Acceptance of a PO by a seller usually

forms a one-off contract between the buyer and seller, so no contract exists

until the PO is accepted.

ii) CREDIT NOTE

A credit note or credit memorandum (memo) is a commercial document

issued by a seller to a buyer. The seller usually issues a Credit Memo for thesame or lower amount than the invoice, and then repays the money to the

buyer or sets it off against a balance due from other transactions. A credit notelists the products, quantities and agreed prices for products or services the

seller provided the buyer, but the buyer returned or did not receive. It may beissued in the case of damaged goods, errors or allowances. In respect of the

previously issued invoice, a Credit Memo will reduce or eliminate the amountthe buyer has to pay

iii) INVOICE

An invoice or bill is a commercial document issued by a seller to the buyer,

indicating the products, quantities, and agreed prices for productsor services the seller has provided the buyer. An invoice indicates the buyer

must pay the seller, according to the payment terms. The buyer has amaximum amount of days to pay these goods and are sometimes offered a

discount if paid before. From the point of view of a seller, an invoice is a sales

invoice. From the point of view of a buyer, an invoice is a purchase invoice.

The document indicates the buyer and seller, but the term invoice indicatesmoney is owed or owing. In English, the context of the term invoice is usually

used to clarify its meaning, such as "We sent them an invoice" (they owe usmoney) or "We received an invoice from them" (we owe them money).



iv) LETTER OF CREDIT

The LC can also be source of payment for a transaction, meaning that

redeeming the letter of credit will pay an exporter. Letters of credit are usedprimarily in international trade transactions of significant value, for deals

between a supplier in one country and a customer in another .The Englishname ―letter of credit‖ derives from the French word ―accreditation‖, a power

to do something, which in turn is derivative of the Latin word ―accreditivus‖,meaning trust. The Application any defence relating to the underlying contract

of sale. This is as long as the seller performs their duties to an extent thatmeets the requirements contained in the LC.

final project report nitin tripathi 1480

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