SAPCO powers up with solar: A sustainable leap in packaging
The new solar installation now powers a large portion of SAPCO’s production facility, reducing dependence on conventional electricity and enabling more responsible operations.
29 May 2025 | By Sai Deepthi P
Solar panels installed at SAPCO (Source: Vishwamdev Bhotica LinkedIn)
Shree Arun Packaging Company (SAPCO), a legacy player in India’s folding carton industry for over 55 years, has taken a significant step toward clean manufacturing by installing a rooftop solar power system at its factory.
The new solar installation now powers a large portion of SAPCO’s production facility, reducing dependence on conventional electricity and enabling more responsible operations.
Environmental Impact
- 60 tons of CO₂ emissions offset per month
- Equivalent to planting 15 trees every month
- Annual savings: 720 tons CO₂, equal to 180 trees
- Potential to generate carbon credits that can be monetized or used to meet ESG (Environmental, Social, and Governance) reporting goals.
The print and packaging industry is energy-intensive. SAPCO’s initiative demonstrates how packaging converters can combine sustainability with scale, efficiency, and quality, without compromising on performance. This transition sets a benchmark for others in the industry to rethink energy usage.
SAPCO Management said that as converters, they can no longer think only in terms of production output — “Every decision must also consider environmental impact. Our shift to solar is just one step in a larger commitment to future-ready, responsible packaging. It’s our way of giving back to the earth, while setting an example for what the print industry is capable of.”
Beyond solar, SAPCO continues to invest in waste reduction, material optimisation, recyclable and mono-material carton development, and all in alignment with global sustainability trends and customer expectations. Since 2021, the factory has used only LED lights, and the travel to the factory is in EVs and hybrid vehicles.
Interview with Vishwamdev Bhotica, technical director, SAPCO
Sai Deepthi (SD): Please describe the installation process for the solar panels. Was it hassle-free?
Vishwamdev Bhotica (VB): Yes, it was fairly straightforward, where we had to take permission from the government and check the structural strength of our roof.
SD: How much MWh do you generate annually?
VB: 500-MWh is slated to be generated annually, considering the weather in our geographical area. With solar usage, SAPCO will cut its grid electricity usage by approximately 30%.
SD: Climate concerns remain a key issue for both consumers and businesses when buying packaging products. How important is SAPCO's shift to a sustainable lifestyle to your customers?
VB: At SAPCO, our shift to sustainable packaging isn't just a choice — it’s a response to what our customers now demand. Climate-conscious businesses rely on us for recyclable, plastic-free, and efficient solutions that align with their values and consumer expectations.
SD: Tushar Bhotica had stated that power and energy are a major source of cost for a packaging converter. What is the maths behind this?
VB: Energy cost is 3-5% for a packaging converter; we have heavy machinery coupled with air conditioning and heaters, and air compressors.
SD: Do you think factories that need a wide floorspace and high daytime demand for electricity are ideal candidates for solar?
VB: Solar cost is proportional to investment budget or area that can be used for solar roofing, so at any scale, it is a smart investment, especially since you are contributing to a greener tomorrow. For example, at SAPCO, we have around 40000-sq ft of solar roofing. And for mid-sized firms looking to invest, it all depends on the area, but the ballpark figure would be about Rs 35-40,000 per KW.
SD: Do you work with an external consultant to examine and execute the project?
VB: No, not at all.
SD: Are you pleased with the results from your solar investment so far?
VB: So far, so good, and we’d recommend it to other businesses looking to reduce their carbon footprint and long-term energy costs.
SD: Have you set a carbon reduction target?
VB: We have reduced our emissions, and our goal is to be more efficient in terms of our usage of electricity, thus being aware and moving towards carbon neutrality.
SAPCO was founded by Narayan Prasad Bhotica in 1970. It was equipped with letterpress and the mandatory hand-platen punching machines. Until 1995, Sapco operated from a unit in Lower Parel with its wrapper production unit. Today, Sapco operates from a single unit spread over a 60,000 sqft site near Kalyan, where it moved in 2021.