ACG's Shirwal facility recognised as global lighthouse by World Economic Forum

ACG Packaging Materials has announced that its Shirwal facility has been recognised as a global lighthouse by the World Economic Forum, marking the second such distinction for the group following its Pithampur capsules site’s induction in 2023.

At the Shirwal plant, the digital transformation programme integrates generative AI, machine learning, deep learning, the Industrial Internet of Things (IIoT), and digital twin technologies. These tools have been deployed to navigate a highly competitive, and commoditised market, allowing the facility to enhance productivity and quality while simultaneously reducing greenhouse gas emissions.

The implementation of these advanced systems has resulted in 40% reduction in lead times, and 71% reduction in defects. Furthermore, the facility has recorded 31% reduction in energy consumption and 34% improvement in on-time delivery.

Karan Singh, managing director at ACG, said, “ACG has always believed that true leadership in the packaging sector comes from building smarter—not competing harder. Our Shirwal facility is now our second site to be recognised by the World Economic Forum’s Global Lighthouse Network, making ACG the world’s first pharmaceutical packaging company to receive this honour.”

Singh noted that the achievement reflects the group-wide commitment to optimising packaging to make medicines safer and more affordable. He added, “Repetition is the test of proof—in line with our make-it-better commitment, we are replicating this Lighthouse excellence across our facilities and pioneering sustainability lighthouses for responsible, resilient manufacturing from India.”

The digital initiatives at the site have strengthened daily decision-making by providing greater visibility into operations. This transparency enables the workforce to respond more quickly and consistently to variations across manufacturing processes.

SR Shivshankar, CEO of ACG Packaging Materials, said, “This recognition reflects the commitment of our teams at Shirwal and their ability to integrate advanced digital technologies into everyday manufacturing operations. It strengthens our focus on delivering consistent quality, productivity, and sustainability for customers worldwide.”

Balajikasiram Sundararajan, chief digital officer at ACG Group, highlighted the broader strategy, stating, “Through our Build the Future programme, ACG is driving technology-led transformation across the manufacturing value chain, enabling smart manufacturing, connected products and services, and new business models. This prestigious Global Lighthouse recognition inspires us to continue scaling innovation across our businesses.”

Kiva Allgood, head of the centre for advanced manufacturing and supply chains at the World Economic Forum, commented on the evolving nature of industrial performance. Allgood said, “Competitiveness today is no longer defined by efficiency alone, but by the ability to sense, adapt, and respond at speed. The Global Lighthouse Network showcases how intelligence-led operations are placing resilience and sustainability at the core of industrial performance.”