“Sicon Packs,” a journey of resilience between Mumbai and Nigeria!

“Sicon Packs,” a journey of resilience between Mumbai and Nigeria!

At the Labelexpo Europe, Brussels in 2007, Tarsus UK, the owners of labelexpo group, announced the acquisition of India Label Show, founded by the husband wife duo Anil and Neetu Arora. It was time to celebrate for Anil, who with industry friends that included the author, industry veteran Amit Sheth and a few others were doing the rounds in the bars and eateries at Grand Place. Grand place in Brussels had a nostalgic connection for the label industry at large, where the printers and suppliers partied each evening after the day-end at the show. The show has since moved to Barcelona in Spain in 2025. That evening, Amit Sheth had brought along a customer, a tall quite man who did not talk much but was extremely attentive, he had business in Nigeria and had finalized his first purchase of a label press from Amit’s company Intergraphics, at the show. He had a unique name, Yudhviram Solanki, which in real terms means ceasefire.

According to Yudhviram, “People are often fascinated by my name which also carries a small story. I was born on 20th September 1965, during the height of the Indo-Pak war. My grandfather was in the Indian army during the war and stationed in Jodhpur. My arrival, I have been told, brought a moment of calm amidst chaos, and just three days later, on 23rd September, a ceasefire was declared by the prime minister of India Lal Bahadur Shastri. That is how I came to be named Yudhviram by my grandmother, it means the end of war.” Yudhviram grew up in a humble family living in the Mafatlal Colony in Thane District of Mumbai. To support a family of six, his father Harisinghji Solanki took on part-time business besides his regular job. His mother Kanchan Solanki was the binding force and a pillar of strength for the family.

As a young boy, Yudhviram Solanki would often watch his aunt sell tiny tidbits to students from her small stall near their school. The way she spoke to customers, the little tactics she used, the energy she carried with each transaction, resulted in profound wish to be a businessman. The joy of creating value, one sale at a time, awestruck him at a very young age. As founder director of Sicon Packs Pvt. Ltd., his journey has been one of resilience, balance, and meaningful relationships built with ambition to grow.

His initial schooling was from St. John, The Baptist High School Mumbai followed by a B.Sc. Degree from BNB College Thane in 1987. Prior to taking up a steady career in the multinational Phillips in 1989, he took up various odd jobs to supplement the family income. The years spent at Phillips were his training ground and learning the fundamentals of achieving excellence in sales, that eventually supported his entrepreneurial journey later. Though Solanki made many friends, one of his college friends Shridhar Prabhu, owner of Dolly packaging, manufacturing corrugated cartons, encouraged him to initiate his maiden venture as an entrepreneur of manufacturing carbon paper in 1995 and supplying to industry leaders like Kores and Camlin, later adding stationery to his range of offerings. They even developed their own brand of carbon Paper “Swan” and “Sailing Boat” to sell in Middle East, European and West African markets.

Manufacturing was from the two factories they set up, one measuring 10,000 square feet at Navi Mumbai and the other 20,000 square feet at Mumbai. Despite carbon paper being a product that was losing market share fast, Solanki successfully ran it for the next 15 years, gaining experience as an entrepreneur. The receding demand for carbon papers made the decision to exit carbon paper manufacturing in 2013. During this time another friend Milind Deshmukh, who was his colleague in Phillips and had moved to Nigeria in 1998, mentored him to start exports to Nigeria. Solanki travelled to Nigeria in 2001 and as life would have it, he suffered a malarial attack on arrival there. He almost decided not to come back to that country, but once he recovered and started working, he was thrilled to find success in shape of an order for two container loads of carbon paper. This was his beginning of business journey in that country. This taught him the nuances of doing business in the West African markets. It was a country with personal safety concerns and lacking infrastructure like power. He started to import stationery from Mumbai and sell there and during the course he also started to trade in labels imported from Mumbai.

Soon he became aware of an increasing demand for labels in the country which was largely being met by imports. He started to sell labels on “stock and sell” basis to provide ease of purchase for customers by buying and paying in local currency instead of imports and dollar remittances. The success this brought, Solanki took the next landmark step in his entrepreneurial journey from trading to manufacturing by establishing Perfect Packaging Ltd.(PPL), one of the first roll form label manufacturing company in Nigeria. Earlier people were producing labels in sheet form, and the quality was not good. Their first order came from Mr. Shekhar Ghate, former Director of Holborn and now Managing Director of Apple and Pears Nigeria. Nigeria has been a difficult market. Over the last decade, the local currency Naira’s drastic devaluation has posed a constant challenge. In 2015, 1 USD was equal to 150 Nairas, and today it stands at nearly 1,600 Nairas. This volatility made expansion and reinvestment incredibly difficult. 

 Additionally, being an import-dependent economy, Nigeria’s planning and payment cycles are complex and unpredictable. Yet, despite these hurdles, the resilience and warmth of the Nigerian people kept the PPL team motivated. The first major breakthrough came when PPL successfully cleared the SMETA 6-Pillar Audit, an achievement that opened doors to multiple international clients. Within just two months, they onboarded one of Nigeria’s largest alcobev brands as a premium customer, setting the tone for many successes that followed.

Following the success in Nigeria, the yearning for replicating it back home, Solanki with advice from industry leader Mahendra Shah of Renault Paper Products Pvt. Ltd. returned to India and with Gautam Shah of Atlanta Forms as a partner, he established his Indian venture Sicon Packs Pvt. Ltd. He reminisces it as a memorable start, the first order for a promotional label came from pharma giant Cipla, though what followed in operations in India had other challenges. These included rising input costs, complex labour laws, intense competition, taxes, and sustainability norms, all of which demand careful navigation.

Early in his career when he started carbon paper business, he married Manjiri in 1995 who has been a support and part of his professional journey. Since the carbon paper business entailed vigorous travel, Manjiri held the fort for him, managing the factories while he travelled for over three weeks every month from 2001 onwards, providing much-needed support. 

They are blessed with two children. Their son Devendra is a qualified computer engineer. Devendra started his career at “Teach for India” where he met Shivani and the relationship flourished leading them getting married, Devendra now leads Sicon Packs into diversification and expansion. Their daughter, Kashish Solanki, holds a Master’s in Analytics and Management from the London Business School and currently works with Apple in Mumbai. Her husband Pratik Dubal is a Research Engineer at Meta.

Sicon Pack’s operations in Nigeria and India have grown. In Nigeria, they operate out of a 40,000 sq. ft. facility with 5 flexo machines employing over 100 people. The Indian plant is spread over 30,000 sq. ft. more than 40 employees and 2 letter press and 3 flexo label presses. Both units specialize in the manufacturing and conversion of self-adhesive labels. The India plant is ISO 9001 & 14001 certified and recently achieved the GMI certification from SGS, enabling them to serve premium brands with strict color and shade compliance standards. Solanki says, “I am grateful to Amit Seth of Intergraphic, who has been a supporter since 2007. All label presses and finishing equipment have been sourced through him. Their quality has been rewarded with LMAI label awards consistently since 2010.

Expansion remaining a key focus they are actively exploring opportunities in Ghana, a neighboring market to Nigeria, and even evaluating possibilities in the United States with an innovative technology base, though this is still at an early stage. They are also contemplating expanding their range of products to include shrink sleeves, IML (In-Mold Labels), Wet glue labels, Mono cartons and eventually, digital label printing at both locations. Committed to sustainability, they aim for at least 20% of total production to use eco-friendly, sustainable label stock. They look at a lot of diversifications in the next 5 years that may also include B2C products.

Outside of work, Solanki’s biggest dream is to go on a 145-day world cruise. He has always loved cruise travel, having been on three cruises already. The last cruise through Alaska in 2018, has been the longest yet. A world cruise looks like the next big adventure and an exciting challenge!

Written by Harveer Sahni, Chairman Weldon Celloplast Limited, New Delhi December 2025

Labelexpo 2025. Evolution of digital labels and packaging equipment!

Labelexpo 2025. Evolution of digital labels and packaging equipment!

In the ever changing and evolving technological advancements in label printing and application processes, change remains constant, leaving very little space to remain complacent. One needs to remain abreast of evolution and stay updated and adopt new developments in whatever way possible. Staying stuck to technologies that are undergoing change, longer than necessary with chance of becoming obsolete,  may bring in a feeling of uncertainty and negativity. 

It does not mean one should immediately forget everything and start changing, but it would be worthwhile to stay abreast and consider accepting indulgence in evolution. In the early 1970s, the author was in process of setting up a factory in the suburbs of Delhi to increase the production of their popular fountain pen inks. Friends in those days cautioned that ball pens are a disruption coming in, however countering that, it was felt fountain pens are here to stay. But what happened is history now, fountain pens are just a show of affluence for some, ball pens rule in mass usage, the fountain pen ink business became negligent and miniscule. Printing technologies in India to produce self-adhesive labels or stickers also transformed from the earliest screen printing manually in sheet form to roll form by letter press, flexo to digital and hybrid. The industry is in that transitional mode of contemplating whether digital will takeover and disrupt. The general opinion in this phase is that both digital and analogue will co-exist as of now. Even digital printing technologies are evolving in multiple tangents. Labelexpo Europe 2025 at Barcelona is around the corner, and it will be good indicator of how the digital label printing and converting is evolving. The author interacted with leading digital label printing equipment providers to understand their presentations at this important show.

At the very outset it is important to understand that while the narrow web label printing has evolved to wider width, it has in its advancement entered the flexible packaging and carton converting arena as well. In the foray into futuristic converting, the digital finishing, embellishment and converting are also undergoing the digital path to evolution. Label printers while considering investments, are not anymore investing into digital presses, limiting themselves to only manufacturing labels, but also considering increasing their capabilities to produce shrink sleeves, pouches, diverse forms of flexible packaging and folding cartons.

HP Indigo: My recent article on Trigon digital Mumbai is an ode to this expanded product range on digital printing and converting. HP Indigo has supported such endeavors and are exhibiting at Barcelona. HP Indigo offers full digital print solutions that enable converters to allocate the right job to the right press. They will showcase the HP Indigo V12 which runs at speeds up to 120 meters per minute and offers full digital print solutions that enable converters to allocate the right job to the right press. Proven to achieve breakthrough milestones in high-volume output, including record-setting runs.

HP Indigo 6K+ that combines a new integrated SmartControlSystem, alongside AI-powered PrintOS tools for greater accuracy, reliability and real-time insights. HP PrintOS, AI-powered solutions and automation software tools to streamline production, boost creativity and accelerate growth. HP PrintOS and HP Nio, users can control workflows form order to shipping, turn data into insight and enhance performance across every operator.

Domino will be at booth 3E91 displaying their latest digital label printing solutions. Ajay Raorane Vice president Domino Printech India LLP says,” With the rise of e-commerce and the government’s push to support startups, we expect Increased demand for quick, high-quality label printing. While India still has a large installed base of conventional printing, the percentage growth of digital appears higher due to a smaller installed base. We feel the trend will grow as more installations happen.” Ajay further expressed that with digital also expanding into flexible packaging, it is a very exciting time for the entire packaging industry. He firmly believes that this is a time of transformation. 

They will exhibit; The Domino N730i, a high-performance 1200 DPI press using their own Brother Bitstar printhead, capable of printing at speeds up to 90 meters per minute. The Domino N610i, monochrome printers, the Domino K600i and the Domino K300, which can print at impressive speeds of up to 150 and 250 meters per minute, respectively. According to Ajay, Digital printing has come a long way. What started as a solution for short runs is now being used for medium and even long runs, where the added value of digital, like variable data printing and image-level personalization, brings real benefits to brand owners.  The presses are getting faster, more reliable, and offer greater profitability for converters. Digital printing can also support sustainability goals by reducing waste, lowering excess inventory, and minimizing obsolescence due to regulatory or consumer changes. This is a time of transformation.

Xeikon will be present in Hall 3 at Labelexpo displaying their Xeikon Titon TX500 20” wide dry toner press, Xeikon PX3300 HD 1200dpi UV Inkjet press, Xeikon LX3000 330mm wide dry toner press. It is a similar range that they displayed at the last Drupa. Vikram Saxena Sales General manager at Xeikon says, “In my opinion buyers for high end digital printing solutions are less, as compared to Europe or North America. Most Indian Label convertors seek low or mid budget digital printing solutions. Lower running cost plays important role for Indian buyers instead of top quality or sustainable solutions.” He further stated that the Indian label printing market will grow by 13.29% CAGR upto 2030 according to Mordor intelligence report and will reach  $4.59 billion by 2030. He stressed the need for awareness regarding sustainability; Indian Label convertors often ignore this point.

Durst Group exhibiting at Labelexpo Europe 2025 Booth E79, Hall 3 showcasing its next-generation digital printing platforms, including both hybrid systems and roll-to-roll configurations. As per the Labelexpo Europe 2025 website, Durst is keeping the details of its new press G3 launch under wraps until the show, describing it as a ‘compact, scalable’ 8-color LED-UV press. Hybrid presses can make use of an almost unlimited combination of digital and conventional print, decoration, and converting units. An example at the Durst stand will be the 9-color 420mm-wide Durst KJET, incorporating the company’s LED-UV inkjet print engine, four flexo units, two multi-purpose lamination units, turn-bar and semi-rotary die-cut.

Durst Indian agent Venkatesh Selvaraj mentions, “The technologies being unveiled are both new and forward-looking, developed to meet the future demands of label converters and the full details will be revealed exclusively at Labelexpo.”

Guangzhou PULISI Technology Co., LTD will be exhibiting at Labelexpo Europe Stand 5D81 displaying Two variants of UV Inkjet Digital Press; 1. Hybrid Digital with Flexo to optimise both Technologies in one press and printers can use this combination for value-addition production of Self-Adhesive Labels, Shrink Sleeve, IML and boards. 2. A standalone UV inkjet press designed for the digital segment, utilizing inkjet technology with a resolution of up to 1200 dpi with addition of Online Digital Embellishment possibility, enables users to address various market needs in label production and flexible packaging.

Amit Sheth Director at Pulisi says, “Digital printing in true sense has so far not fully evolved as an acceptable technology for both short and medium to long run jobs. Digital is growing but considering its pros and cons, one must learn and then decide as in reality it is not just that at touch of a button you print what you need. There is a lot more to consider.

Monotech Systems Ltd. will be exhibiting at Booth E50 in Hall 5. Showcasing running live, their advanced Track and trace solution – Tracesci® Loop a compact tabletop system for variable data printing, code connected packaging, brand protection and consumer engagement. In addition, they will display high-quality printed application samples from their digital inkjet label press JETSCI® KolorSmart+ and the dSpark digital embellishing and finishing system.

T P Jain Managing Director Monotech says, “Digital label printing in India is witnessing steady and accelerated growth with increasing demand for shorter runs, personalization, faster turnaround times, and high-quality output driving adoption across multiple industries. While conventional printing will continue to dominate in terms of overall volume, digital will outpace conventional in percentage growth. Digital label printing is no longer just about speed and quality it’s evolving into a platform for intelligence, security, and brand engagement.”

Arrow Digital will be exhibiting at stand 4A10. Showcasing Arrowjet water-based digital pigment ink label printer with in-line primer coater. It is a futuristic sustainable solution which printers are looking for. This press available in 330mm and 700mm can print at a speed up to 150 meters per minute.

While digital is now growing and if we talk of percentage of growth, it looks robust because at the smaller base number of about 70 to 80 presses from established brands a 15% growth rate translates into just 10 to 12 presses in a year. However, it is interesting to note that in a large customer base, not just the bare population of the country but the printing companies that are operational in the packaging space, digital once the adoption starts will grow fast.

Already the widths have grown wider, and the speeds have gone up to 120 meters per minute. The economies of scale may eventually trigger the downward trend in cost of consumables. The preference of going beyond the CMYK regime using Extended Color Gamut (ECG) printing to  reproduce a greater percentage of Pantone spot colors, increases possibilities of catering to a wider range of package printing needs. While it is a fact the digital is just a fraction of the conventional or analogue printing but now that digital is finding acceptance, it will remain an industry to watch.

Written by Harveer Sahni Chairman Weldon Celloplast Ltd. New Delhi

Faridabad, a hub for label presses part-1-The Printers House!

Faridabad, a hub for label presses part-1-The Printers House!

The last Labelexpo India 2022 was witness to an interesting evolution in the display of high-end label printing presses. For the first time since the inception of this show, the European and American presses running live were missing.

However, the flexo presses displayed at this all-important label exhibition were made in India. This was an indicator towards the Indian press manufacturers to have come of age. These Indian manufacturers are now, not only announcing sales in India but also succeeding in the global label arena. An interesting part of this evolution is that most of the successful brands of flexo presses that have been developed come from Faridabad, the neighboring industrial suburb of New Delhi. Faridabad is a part of NCR Delhi and a major industrial hub of the state of Haryana. It is famous for henna production from the agricultural sector, while tractors, motorcycles, switch gears, refrigerators, shoes, tyres and garments constitute its primary industrial products. There is reason why most of the leading brands of Indian made flexo presses are from this city. These presses include Multitec, Webtech, NBG, Label Flex and many other smaller ones. Even UV Graphic technologies now headquartered in NOIDA, started their manufacturing in partnership with Faridabad based Multitec. 

The credit of printing equipment manufacturing industry flourishing and growing in this city goes to the establishment and transformation of a company founded by Kishan Das Kohli, a man who fought for the independence of India prior to its partitioning.

The Printers House now renamed as TPH Orient group was founded by Kohli in 1946 as an agency house bringing global printing technology to India. He was responsible for installations, commissioning, providing technical expertise and operators for the imported equipment. For the pioneering work he did for the printing industry in India, he received numerous awards that included the Kohinoor Ratna award. An enterprising businessman, he started manufacturing printing presses in India in the mid-1960s initiating his maiden startup manufacturing unit in Faridabad to build letterpress and offset printing presses there. Around this manufacturing unit, an ecosystem of mechanical engineering professionals and engineering companies was built and went on growing. Many companies now making flexo presses or any other type of presses in Faridabad first started out as their vendors. Making any type of press requires components such as frames, cylinders, etc.

The Printers House helped create the infrastructure and this supply chain in Faridabad, which is what makes it ideal for printing press manufacturing hub. Later another company Sud and Warren led by Baldev Sud, Arora and Ahuja  also commenced manufacturing  slitting machines and later web-based computer stationery. The company did not grow as envisaged and some of their ex-employees are now narrow web label press manufacturers

I, the author, having had two factories in Faridabad since the 1960s, producing stationery and silicone release papers under the brand Weldon, had  heard a lot about The Printers House and the kind of work they had done. Weldon’s vendors in earlier days used to print their packaging on the old traditional treadle presses and when the Mercedes automatic presses from TPH were launched, it was a game changing moment. The author reminisces an evening during a party in connection with Printpack India in 1991, he was introduced a tall smart man who was surrounded by print industry stalwarts of that time. He was  Manmohan Kohli, heading The Printers House (TPH) and was the son of the founder K D Kohli. Manmohan was an alumnus of ETH Switzerland, a university of science and technology from where he passed out as gold medalist engineer.

He pioneered the evolution of printing technology in India. Under his leadership TPH became a name to be reckoned with globally, having installations in over 60 countries. Manmohan Kohli, a legend in Indian printing equipment industry,  passed away in June 2022 at the age of 83 years passing the reigns of the company to his only young son Rishab Kohli who now aged 28 years heads TPH as Managing Director.

The first few years of Rishab’s schooling were at New Delhi based Sanskriti School and thereafter he was sent to Gordonstoun school in Scotland. Finishing school in Scotland, he joined Georgetown university in Washington DC where he studied economics and had the opportunity to go through numerous internships in Washington DC including prominent lobbyist firms and international organisations. Completing his education at university, he initiated his career in the United States in finance/investment banking in the US where he worked between the US and Europe extensively. Thereafter he returned to India and in 2020 he took over the reigns of The Printers House now renamed The TPH Orient group, as CEO. Backed by his experience and pedigree in business he envisioned to create a group of companies in India that would cater to the printing , packaging, and other industries.

On assuming the leadership in TPH, Rishab worked with numerous partners across the globe to acquire technology and bring it to India. He saw the label segment growing rapidly and felt there is high reliance on imports on capital equipment in this segment. On his indulgence, TPH  launched their flexo and inkjet label press, extending their application to packaging as well. Given the infrastructure available at TPH, Rishab has decided to produce equipment with economy of scale to make it cost effective and such that customers feel secure with their investment and service. He felt the technical expertise to produce flexo and digital label presses of global standards was still needing upgradation, so he or his team travelled to acquire appropriate technologies.

Rishab mentions that development of the first fully digital ink delivery system made by them in India that successfully printed a full color label at high speeds is huge achievement for TPH. Being the first of its kind developed in India, it will remain as one of the most memorable moments. With the ability to print at 1200 DPI with in-house dynamic RIP (RIP stands for Raster Imaging Processor software), it is a prime competitor to the established leaders in the field of digital label printing. He gives credit for support, guidance and help to the late Ramani Vishwanathan who was a pioneer in digital printing in India. He helped Rishab create this technology. Justifying his move into Digital label printing equipment he states that Inkjet is crucial for label printing due to several macroeconomic factors and market forces. With the rise in short run jobs and customization in packaging, a roll fed digital press is crucial to meet the needs of end clients. Additionally, with the speeds of inkjet presses increasing and head technology advancing at the pace that it is, the mid to long runs may also be catered to by inkjet.

As regards the flexo press developed by them, he asserts, “It is the fastest Indian made machine of its kind at this moment. Additionally, we offer sleeve technology and narrow web along with wider width options.”

The TPH Orient group is now a diversified group of companies and a market leader in printing machinery, packaging machinery , printing consumables , engineering services for defence, aerospace, and solar. They have 800 employees spread over a 20-acre campus and 6 factories in Faridabad working in numerous segments. They also now manufacture inkjet presses, flexo presses, folder gluers, web offset presses, printing chemicals etc. They have one of the largest CNC machine shops in north India and perhaps largest in Faridabad. According to Rishab, TPH Orient group is the largest Indian exporter of printing machines with exports to 60 countries. They have service engineers and offices in 12 locations in India and presence worldwide. They are considering extending manufacturing operations in foreign locations.

Talking of challenging times in his short career, Rishab says, “Covid was a tough period, but we got through it, taking every day at a time. But a lot was learnt, and we came out of it stronger.” In his journey so far, a key member of TPH board of directors, Naveen Chahal, has been a mentor to him. Being an extremely experienced person, his guidance has helped the turnover grow to over 15 times the figure when Rishab took over. In printing and packaging Rishab acknowledges the guidance of Christoph Mueller, director Koenig and Bauer, for his guidance in quality enhancement of their products.

Rishab Kohli sums up his vision for the future as, “The key for Orient in the printing and packaging industry is to provide a holistic solution to the printing and packaging community worldwide. We have a simple goal which is to be the largest equipment supplier in our field coming out of India and ideally Asia in this segment. With our infrastructure , scale, and history this is a realistic and an important 5-year goal.”

 Written by Harveer Sahni, Chairman Weldon Celloplast Limited New Delhi August 2024

Driving profitability in labels!

Driving profitability in labels!

 Driving profitability in labels, with embellishments, digital printing & hybrid printing

Self-adhesive or pressure sensitive labels industry in India has grown steadily right from the time of its initial entry into India to be indigenously produced in the mid-1960s when a screen printer manually created the first label. Thereafter, label manufacturing has evolved and completely transformed  technically over the years. Initially, small and slow very narrow web letter presses, 4 or 5inch wide, from the eastern part of the world were used to print with blocks and die-cut labels with flatbed dies in roll form. These presses eventually started going wider in printing width with growth in demand. The need for increased production in 1980s brought in the adoption of rotary flexographic printing presses. However, since the flexo plate technology was just evolving, usage of letterpress block printing was still growing. It was in the new millennium that developments brought in prepress and plate making technologies, made it possible for printers to decrease their dependence on letterpress printing technology and invest in flexo presses that eventually became modular and print widths going wider with increased speeds.

Toward the middle of the first decade of the new millennium, the pop and Mom retail stores, known as Kirana stores catering to consumers, started being replaced by the entry of organized retail outlets and with it, came the increase in demand for labels and packaging. When it was realized the customer’s point of purchase decision to lift the product off the shelf is the driver for sales, brands felt the imperative need for attractive labels and packaging. Different print technologies started being employed and presses with advanced capabilities started being developed and offered. While all this transformation was happening, the label industry in India was all along registering a robust double-digit growth. It was largely accepted fact that even though labels are a very small part of the large packaging industry, it was more profitable. Due to this, the number of label printers kept growing, investments also came in from established offset printing companies. With cheaper label presses coming from China and availability of good affordable machines in India, the label printing capacities have grown exponentially. This increase in capacities, the pandemic, the strikes in Finnish paper mills, the Ukraine war, the re-emergence of Covid in China,  etc. brought the margins in the labels industry under intense  pressure. Raw material prices have since escalated, freight rates, salaries and overheads have increase while competition does not leave room for increase in selling prices. In such a difficult scenario, label converters are looking at options to drive in profitability.

Opinion and comments of label printers across India was sought on how to drive-in better margins in the label production in the given circumstances. Three questions were posed to all, their response is somewhat similar, yet some do have apprehensions about the steps that are suggested whether they will actually drive in margins? However still, a direction on the way forward appears to be an imperative. The  printers in the diverse geographical zones who contributed their views are as follows;

North:

Anuj Bhargava, Kumar Labels NOIDA hereinafter referred to as (AB)

Rajeev Chhatwal, Kwality Offset New Delhi (RC)

West:

Mahendra Shah, Renault Paper, Palghar (MS)

Himanshu Kapur, J K Fine Prints Mumbai (HK)

Priyank Vasa, Unick fix-a-form, Ahmedabad (PV)

East:

Manoj Kochhar, Holoflex Kolkata (MK)

South:Raveendran Selvarajan, Seljegat Sivakasi (RS)

Lakshminarayanan Parthasarthy, Signode India Ltd. (Wintek) Bangalore (LP)

Question: Do you agree that Embellishments, Digital printing & Hybrid printing or converting are important steps to get better prices for labels?

AB: Yes, value added labels do add to margins. However still, the main buyers are few. Startups or premium products cannot add volumes where multiple players offer value additions. 

RC: Embellishments certainly will get you a better price if you have a technical edge over your competition. Just a  different printing process does not get you more price from customers. One needs to decide which process to use to get better return based on machine capabilities .

Hybrid is still not suited for the Indian Market. However good converting and finishing is important for short runs on digital to reduce wastage.

MS: Yes, I agree. With increase of just-in-time orders, shorter runs and demand for innovations,  it is economical and faster to produce with Digital printing. Embellishments complemented with other capabilities, aid improvement in value addition.

HK: More technical the labels are, better is the margin. Unfortunately, large companies expect more for less. The basics of costing has been lost by most label converters. Embellishments also add to costs, but to recover those costs is difficult.

PV: We aim for the best process fit for a job, be it digital, flexo, hybrid or offset. That is the only way to master production cost. Digital embellishment always gives an edge and keeps business secure but does not always guarantee increased profitability, it comes with its own limitations. 

MK: I agree that Embellishments, Digital printing & Hybrid printing or converting are important steps to get better prices for labels. Value addition invariably leads to a better realization. Brand protection elements such as hologram, security inks, security designing also add value.

RS: Not only embellishments, but also innovations along with having capabilities for attending to needs of customers are important. If food and pharma customer needs labels with water-based inks, we need to have those capabilities. If they need booklet labels it becomes an imperative to be able to create them. Every printing process has its own specialty so when you are able to create labels with Hybrid and digital technologies, then of course selling prices are better.

LP: QR codes and AR (Augmented Reality) in labels, connecting consumer to the brand – is what we see as way forward for profitability . Embellishment leads to aesthetics, shelf appeal, increased sale and brand value for better profits to the buyers and converters.

Question: Have you taken any steps in this direction to increase your capabilities?

AB: We are always focused to value added labels. We have capabilities do embellishments like 3-D effects, embossing, textured foiling, screen printing and many other such processes that enhance the aesthetics of product.

RC: We have already invested in converting equipment with finishing and embellishing capabilities like foiling, Screen printing, Lamination etc. Our range of labels includes- Foil stamped/embossed labels, labels with tactile effects, Laminated, 3-D embossed, Variable data and Holographic labels etc.

MS: Since long, our customer profile is such that embellishments and employment of multiple print technologies is an imperative, for this reason we invested in hybrid presses many years back. Currently to achieve just in time capabilities we are investing in digital printing which will also give us additional production time on our main printing presses.

HK: We have always invested to be a capable company, right from inception so have the capacity to do all types of embellishments.

PV: Yes, we have added digital capabilities. Having multiple printing technologies at our disposal, enables us to pick and choose processes that are best suited for a particular job depending on the complexity of decoration required. 

MK: We are constantly trying to scale up our capabilities of adding diverse authentication features and other embellishments such as foiling, registered hologram stamping, variable data printing and finding new materials that are unique.

RS: At Seljegat we always endeavour to stay invested and capable with the latest developments. We have already installed machines with multiple capabilities, and we prefer all inline. We can do embellishments, special varnishes, multilayer labels, digital for variable or personalized labels, embossing, etc. We are always ready to cater to the changing needs of customers, nowadays pharma and food companies are demanding labels to be done with water-based inks or low migration inks, we have immediately empowered ourself suitably to serve them. In today’s time if we cannot deliver that extra, then we get lost in the crowd of intense competition.

LP: We are already having all capabilities and exploring AR in labels as next step towards Brand connect and Brand promotion. 

Question: What in your opinion are factors that can drive in better margins? Please mention steps at given prices of inputs.

AB: Label companies should invest in making labelstocks for captive use, negotiate hard while buying machines and for buying raw materials.

RC: As competition gets aggressive, systems need to be designed to reduce wastages, increase productivity and buy raw material at competitive prices. Making our internal systems strong is the only way out to drive-in better margins.

MS: We started the process of optimizing production costs, long time back. We collected data of all ongoing jobs for past 3 years and calibrated all processes as per the following;

a) We dwell on actual time needed for the job and check if the processes are complying with targeted numbers.

b) If not complying what’s the core reason and if for some reasons not meeting norms,  can solutions be found?

c) Evaluating, if no solution is possible, is the job generating profit for the company? 

d) If not , either get the price increase or discard such jobs to save time for more sustainable jobs.

HK: Rather than controlling the input prices on which we have no control, we should focus on getting better prices from clients. We need to factor-in the basics like label waste that is completely non-recyclable and cannot be salvaged. Label machines are capital intensive we must add the impact of cost of investment in the total price of end product.

PV: To improve profitability;

Freight cost management is an imperative, it can save lot of money.

Process improvements and wastage control is necessary. One should start with small steps like exact web sizes, proper sheet layout, special sizes for volume jobs, ink management and keeping a track of low moving stocks.

Refrain from unhealthy competition.

Learn from your mistakes as a team. Take all complaints seriously. Try implementing simple solutions. 

Update monthly  performance chart of individual operators,  give them incentives for faster turnaround and increased capacity utilization. Take corrective steps to reduce downtime due breakdowns. 

·      MK: Key to improve margins is to provide customised solutions by understanding what the customer needs. We try to incorporate various levels of authentication, embellishments and decoration to tailor solutions that best meet their needs. If a customer cannot afford to pay for the hologram, we focus on enhancing the printed authentication features keeping costs under control, and yet get a price that enhances our profitability while the customer appreciates the value we deliver.

RS:  For driving in better margins, the instant reaction is to buy cheaper but if we have to think of steps at given raw material prices then one has to research internally and implement changes. As a first step we have opted for equipment and steps for faster changeover time between jobs to increase productivity. We have invested in a system for make ready to be completed before one job ends. The changeover time for us has reduced from one and half hour to just thirty minutes. For job set up we were using fresh labelstock but now we use rejected, old and leftover unusable stocks. Next, we are now switching over to LED UV as its operational and lamp replacement cost is lower. New equipment has been ordered and will be installed soon. We plan to install an automatic butt slicer for non-stop production. Reducing wastages is also on our radar and we constantly work on it.

LP: The following steps are necessary to drive in profits;

Watertight operations, control on wastages and minimising set-up waste.

Reducing overhead costs, improving efficiency and OEE (Overall equipment effectiveness).

Propose embellishments to customer making the label more premium to claim better realisation.

Summation:

Price increase is an ongoing process, the impact of inflation is felt every year along with that of other unavoidable circumstances. So, manufacturers need to gradually increase selling prices to maintain a healthy bottom line. Unfortunately, that is an ideal scenario but in actual the selling prices are driven by market dynamics and competition. In the present situation, for the label industry, it is time to look internally and evaluate. Based on the views of the printing fraternity it is largely agreed that embellishments, security features and innovative concepts on labels that enhance the shelf appeal and lead to better sales volumes for brands, can help get better prices. The simpler the label is, more is the competition. As indigenously produced label presses have come within the reach of middle level printers, the competition in that segment has become intense. Moreover, with organized retail and ecommerce becoming the predominant selling systems, need for more decorative labels, IT enabled labels and personalized variably printed labels  with security features has escalated.

Not long-ago setup of label jobs took an hour or more with 2 or 3 persons on each press and at least 100 meters of material being used before final saleable production commenced. With increased automation, advanced automatic registration controls, higher speeds, etc. now a single operator can setup a job in just a few meters in about 15-30 minutes, with increased productivity, less wastages and quick changeovers between jobs by keeping the next jobs ready. Using exact size materials and not generating offcuts is also a necessity. These are changes that add to margins and reduced operational expenses.

Food and pharma safety and health concerns are matters of importance for discerning customers, this, along with statutory rules for toxic or unsafe materials used in converting labels, are to be avoided. There is an increased demand for non-migration and water-based inks because UV inks are considered somewhat hazardous for direct food contact and skin contact applications. Printers need to have such capabilities to supply as demanded by print buyers. Most companies feel that to reduce costs there is need for internal production systems and the workflow to be strengthened or monitored continuously to reduce downtimes at each stage, opt for more automation to reduce manpower and use energy efficient machines, equipment or systems.

Finally, time has come when EPR (Extended producer responsibility) compliance has become mandatory. Sustainability and circular economy are becoming a social responsibility for earth to be a safer planet. Large FMCG companies and brands have already started opting for or expressing preference to buy from certified green companies. It will not be out of place that producing in compliance, may as well add to cost but it may also qualify for better pricing for this good social cause.

Written by Harveer Sahni Chairman, Weldon Celloplast Limited, New Delhi February 2023