New juice plant planned for North East India

Shrey Agarwal, director of Surya Fresh Foods. Photo PSA

The juice brands are doing well. "During peak season of the year, the iv Tetra Pak lines installed six years agone, produce virtually 1.5 crore (15 1000000) juice packets every calendar month. A year ago, we have also added PET bottling lines for juice packaging," says Shrey Agarwal, director of Surya Fresh Foods. "The juice market is growing and in the nutrient industry, you volition not exist able to grow only by sticking to a single category. We see a good potential in the juice market which is growing at ten to 15% per annum and that is one of the reasons whey we diversified to the juice segment. The aim is to make our juice products one of the best brands at a regional level while competing with regional companies," says Agarwal. At present, Surya Foods supplies its packaged juice to about 19 Indian states with plans to expand in North E India with a new plant. Agarwal says, "The transportation price to the nooks and corners of the North East is high and hence we are planning to commencement a new found there. Gradually, we will take a pan-India presence and add together another new institute in Southward India."

Beige packaging – flexibles and monocartons
According to BP Agarwal, chairman, Surya Fresh Foods, the company produces 600 tonnes biscuits, cookies, chocolates and cakes daily. "The biscuit plant in Greater Noida is i of the biggest biscuit plants in Asia," says Dinesh Prasad, plant manager of the print and packaging partition at Surya Foods. "Nosotros produce and pack 11 varieties of biscuits simultaneously and that is no pocket-size thing."
The adjacent flexible packaging establish converts effectually 300 tonnes of flexible textile monthly for packaging of Surya's biscuits and has 2 eight-color Rotogravure presses – an ExperPac 4000 with electronic line shaft installed in 2022 which runs at 300 metres a minute and an ExperPac 2000 with a rated speed of 200 metres a minute. Alongside there are ii lamination machines and two slitter-rewinders. "The ink we employ on our presses is food grade ink," says Manoj Sharma, institute manager of the flexible packaging unit at Surya Fresh Foods.

In 2015, Surya Fresh Foods installed a 'dream automobile' – a Rapida 105 half dozen-colour plus coater full UV offset sheetfed printing at the Greater Noida establish. With three interdeck and i terminate-of-press UV curing system, the Rapida is rated at xvi,000 sheets an hour. The printed sheets on it are converted to monocartons for biscuits by a Bobst Novacut 106 diecutter and the Bobst Lila 106 A2 binder-gluer. Litho-laminated microflute cartons are produced using a Chinese canvas laminator from Boagang Machinery. "We are converting effectually 20 to 22 lakh sheets of size 28 ten 48 inches every month," says Dinesh Prasad, plant manager of the impress and packaging division at Surya Foods. "We are also using our printing-packaging unit of measurement for packaging job work for other companies."

During superlative flavour of the year, the four Tetra Pak lines installed six years ago, produce well-nigh 1.5 crore (fifteen million) juice packets every calendar month. Photo PSA

Leveraging in-business firm press-packaging
"The in-business firm printing and packaging ready removes all disquisitional issues of quality, timely delivery, operational flexibility and security. The greatest advantage of having an in-house packaging unit is the control and flexibility than can be gained at different levels of production," says Prasad. The half-dozen-color UV Rapida generally prints CMYK and two special colors for biscuit cartons. "I of the special colors is our base of operations color which could exist blue, chocolate-brown or orangish and the other is a brand color we employ for our logo," says Prasad.
For the Priyagold biscuit cartons, the lead time has come up down drastically with production becoming more than organized. "Earlier, when there was a shortage of packaging material, information technology took the states around 10 days to go the material shipped from the supplier. However, now we are capable of forecasting demand iii days in advance and evangelize the cartons to our beige manufacturing plants just-in-time. Nosotros also have the choice to pick and process jobs on the basis of priority," says Prasad. "With the new KBA 105 half dozen-color plus coater UV press, the color quality and consistency of the cartons has improved manifold and and then has the brand visibility. The new press gives us the flexibility to maintain our brand logos and other crucial elements while calculation embellishments and special colors when needed without the lead times and hassles faced by us when we outsourced our packaging."

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