WhatPackaging - Latest Articles

More per metre is the mantra at UFlex

Sai Deepthi P — Wed, 09 Apr 2025 16:56:00

UFlex showcased two of its best-selling machines: the UFlex CT-140, a high-speed servo-driven vertical form-fill-seal machine, and the UFlex PFS-240, an automatic pick-fill-seal machine. In an interview, Sumeet Arora, senior vice president, sales and marketing (engineering business), UFlex, shared what sets the company apart and ahead of its competitors.

Sai Deepthi (SD): What’s on display?
Sumeet Arora (SA): Today, packaging is no longer just about enclosing a product. Three decades ago, it was mainly about ensuring safe delivery. Now, it plays a crucial role in extending the product's shelf life and enhancing functionality. We’ve displayed the vertical form-fill-seal machine, where the product is fed vertically into a formed bag. This machine runs at 140 bags per minute, making it one of the fastest on the market. It's also considered the "zenith of flexibility" in bagging, capable of handling a wide variety of products.

On the other hand, we have the automatic pick-fill-seal machine, one of the most exciting innovations in our portfolio. There is a growing trend toward using pre-made bags, which are not only visually appealing but also designed to be easy to open. Packaging today has evolved to offer product protection, longer shelf life, and consumer confidence, ensuring that buyers know they are purchasing a genuine product.

SD: What’s UFlex’s USP?
SA: Five to ten years ago, a speed of 100 bags per minute was considered a benchmark. We then collectively advanced to 120, and today, we are working toward achieving a solution that delivers 160 bags per minute. What gives UFlex a unique advantage is that we manufacture our own films. This allows us to tweak the laminate properties, such as tackiness, heat sealability, or thickness, to align with the machine speeds we aim to achieve. This vertical integration gives us a significant edge over competitors.

SD: What makes this machine special?
SA: When this technology was first introduced, most machines in the market were imported. UFlex machines, however, are 100% made in India.

SD: What are the challenges in developing a 100% Make in India machine?
SA: While there was no direct demand for a high-speed machine, we chose to take the initiative because we closely follow market trends and understand the evolving needs of our customers. If you were to rely on older machines, you might need 20 machines to meet your production targets. With our high-speed machines, you can do the same job with far fewer units, leading to substantial savings not just in capital investment, but also in floor space, utilities, manpower, and overall cost of ownership.

SD: What about sustainability?
SA: Sustainability is not just a trend—it’s a collective responsibility that requires action at every level. The environmental challenges around us, from littered streets to overflowing landfills and the growing concern of plastic waste, are clear reminders of the urgency. At UFlex, we believe that real change happens when awareness translates into action. UFlex is fully prepared to scale sustainable solutions and technologies, whether through innovation in recyclable packaging or investments in circular economy models. Our focus is on being solution-ready, always.

UFlex's pyramid of efficiency

Speed
Goal: Maximise output per square metre
Why? Fewer machines = lower costs (land, manpower, utilities)

Flexibility
Goal: Handle diverse products (shapes, sizes) on the same machine
Why? FMCG brands (e.g., Haldiram’s 1,000+ products) need adaptability

Accuracy
Goal: Zero giveaways; exact measurements (e.g., 40g = 40g)
Why? Profit protection + customer trust

AGI’s Rrajesh Khosla on India’s cosmetics market and glass packaging

Ramu Ramanathan — Tue, 25 Feb 2025 13:49:00

Ramu Ramanathan (RR): What is your view about the cosmetics market, and your role at Cosmoprof India 2024?
Rrajesh Khosla (RK): India's cosmetics market, valued at approximately USD 15-billion, is experiencing significant growth, driven by social and economic factors. Increase in women empowerment across various sectors is contributing to this expansion. At Cosmoprof India 2024, we aim to showcase our innovative packaging solutions that cater to this dynamic market and support its continued growth .

RR: True. What about male grooming?
RK: The growing male grooming market reflects a broader understanding of the benefits of personal presentation. Cosmetics are now seen as a universal tool for enhancing self-confidence and making a positive impression, which can have a significant impact on both personal and professional life. This trend is driven by a growing desire for self-improvement and self-expression.

RR: Why is glass so crucial to the cosmetics industry?
RK: In the cosmetics industry, where purity and premium image are paramount, glass is the ideal packaging material. Its inertness ensures that delicate formulations remain uncontaminated, while its inherent elegance elevates brand perception. AGI's expertise in glass packaging allows us to effectively serve this growing market

RR: How so?
RK: India is a becoming a major manufacturing hub for the world. The markets in Europe, the United States of America, and Japan are ageing with higher average ages in those regions. Because of this, India has become a hub. Most of our population is under 30 years of age. While many are currently studying in schools and colleges, they will soon enter the workforce. Manufacturing is key to engaging this young workforce, and cosmetics is one of the industries contributing to this growth.

RR: What strategies is AGI implementing to stay competitive in the glass industry?
RK: In the glass industry, maintaining competitiveness requires significant capital investment. AGI addresses this by focusing on two key areas: optimising internal efficiencies and embracing advanced technology. We're committed to leveraging the best available technology to produce high-quality glass products that meet stringent global standards. This commitment is crucial for staying ahead of the curve and maintaining a strong competitive position in the global market

RR: Which segments are you investing in?
RK: Our capital expenditure is focused on enhancing our operational efficiency and expanding production capacity through strategic de-bottlenecking initiatives. This investment ensures we can continue to provide high-quality glass products to meet the growing demands of the market.

RR: Who was your target audience at the Cosmoprof show, and how do you plan to support them?
RK: At Cosmoprof, we were focused on engaging manufacturers of primary and secondary packaging who export to key markets like the US and Europe. We understand the specific challenges these businesses face, such as meeting stringent quality standards and navigating complex regulations. We offer a range of support services, including technical assistance, manufacturing expertise, and access to our advanced production capabilities, to help them overcome these challenges and thrive in the global marketplace.

Khosla: Staying competitive in the glass industry demands major capital investment

RR: What about exports? How do you compare to Chinese competition?
RK: We see significant export opportunities, particularly as environmental regulations become more stringent in regions like Europe and the US. While China remains a key competitor, AGI is strategically positioned to serve global markets due to our favourable political and economic environment.

RR: What is your company's strategy regarding the domestic market versus exports?
RK: Companies adopt different strategies. Some companies focus heavily on exports to boost revenue or profit, but that’s not our approach. For us, the Indian domestic market is a top priority. Of course, we are a commercial organisation, and to remain profitable. However, any company that caters to the domestic market is generally on a stronger footing as opposed to one that banks on exports.

RR: What does high-quality glass production mean in today’s time?
RK: High-quality glass production today means meeting stringent quality standards across diverse applications. This includes precise dimensions, consistent quality, superior strength, and aesthetic appeal. AGI is equipped to deliver this level of quality across various segments, from alcohol bottles and decorative glassware to comprehensive packaging solutions for the cosmetics industry.

AGI leverages a favourable political and economic climate to serve global markets.

RR: What do you mean by total solutions?
RK: By 'total solutions,' we mean providing a complete, ready-to-fill packaging solution. For example, a perfume bottle requires multiple components, including the glass bottle itself, the cap, and any decoration like metallic printing. We provide all of these, so the customer simply needs to fill out the product and apply the closure

RRajesh Khosla: Security caps and closures

We have a dedicated manufacturing plant and team for security caps and closures. This is important to the liquor industry. There are two reasons. One is to protect the revenue of the government, which is public money. The other reason is health because spurious liquor can be packed and contaminated, which is a serious problem.

In India, every state has its excise policy. What happens is that bottles are counterfeited, by collecting used bottles, recycling them by removing the cap and using a counterfeit cap. This gives easy access to a counterfeiter to make a new cap. The closures we produce have high security, high pullout, and high non-refillable. In other words, they have features that will destroy the closure completely.

The counterfeiters cannot use any of the components of the caps that AGI produces. They must buy new caps; in which they have to approach us or invest. Investment is not possible because the caps we produce are made using high-end technology. Counterfeiting is rampant in states like Bihar and Gujarat.

The only way to counter counterfeiting is to make closures which need high investment, out of reach of the counterfeiters, and so complex that the counterfeiters cannot use any of the parts once used. We are pioneers in this technology, and we are also making inroads into non-liquor products in the food and pharmaceutical industries which are also seeing a lot of counterfeiting.

RR: Tell me about your factories.
RK: AGI operates three specialised manufacturing facilities for glass bottles. Our Bhongir plant focuses on packaging for the cosmetics and commercial sectors, while our Hyderabad facility is dedicated to commercial glass production.

RR: What kind of innovations are you working on at your R&D centre?
RK: At our dedicated R&D centre, recognised by the Government of India, we're driven by a commitment to both sustainability and enhanced product performance. We're exploring innovations such as optimising serum bottle designs to reduce waste and developing specialised glass packaging for skincare and haircare with advanced coatings and structural designs to improve product protection and shelf life.

RR: Very interesting, so your R&D is not just working on products …
RK: Absolutely correct. Our R&D takes a holistic approach, focusing not only on product innovation but also on optimising our environmental impact and operational performance. This includes research and development in areas such as sustainable materials, waste reduction strategies, and process improvements to enhance efficiency.

RR: At sustainability conferences, we rarely hear a voice from the glass packaging industry. How do you view your position in the packaging industry compared to other materials like flexible packaging or PET?
RK: Glass occupies a distinct position in the packaging industry, particularly for applications requiring purity, premium presentation, and sustainability. While other materials like flexible packaging and PET serve different purposes, glass is indispensable for products like perfumes and vials, where its inertness and recyclability are crucial. We don't compete directly in those overlapping areas; we focus on delivering the unique benefits that only glass can provide.

RR: What is your perspective on the environmental and health impacts of plastics? Isn’t the time apt, to inform all the stakeholders: the customers, the government, and others?
RK: Absolutely. Be it pharmaceuticals or beverages, everyone talks about the plastic industry in the context of the environment. While much attention is given to the environmental implications of plastic waste, we must also focus on the long-term health risks posed by microplastics entering our bloodstream. With a population of 140-crore, it’s important to ensure that everyone is healthy, productive, and contributing to the economy.

RR: When it comes to messaging, is there a mantra that you would like to give on behalf of the glass industry?
RK: We are yet to form those catchy mantras. As the president of the All-India Glass Manufacturers' Federation (AIGMF), I believe we need to have a collective discussion within the industry. However, the overarching message is clear: if we don’t open our eyes today, we’ll pay a heavy price tomorrow. It’s critical to inform all stakeholders to give packaging the respect it deserves.n

The Big Interview aims to demystify packaging and showcase its potential

Sai Deepthi P — Tue, 04 Feb 2025 17:02:00

Packaging is often called the silent salesman. According to a market report, the B2B packaging market in India was valued at USD 50.5-billion in 2019 and is anticipated to grow to USD 204.81-billion by 2025, with a CAGR of 26.7% from 2020 to 2025, showcasing its huge potential. The Big Interview series offers viewers a well-rounded understanding of this growing industry—practical insights, case studies, packaging applications across various sectors, and future projects. It aims to bridge the gap between products and customer experiences.

In the first instalment of the series, Rupesh Shah, founder of Aarem Engineering, discussed what's driving a leap in productivity, boosting output at Aarem as the company goes on to record an impressive year-on-year growth. The company is transitioning from semi-automatic to fully automatic shrink wrapping and stretch wrapping machines. Shah said, "There was a trend about 10-12 years back where people were working with lower economics, so they wanted semi-automatic machines, now that has changed. Over the last period of five-six years, unit economics have become a volume game, so now they need to pack volume up, with automatic machines to suit their requirements. We have a complete in-house designing department to make those machines."

In the second instalment, Prasad Kulkarni, general manager of commercial industrial at Nilkamal, highlighted the growth of the coding and marking equipment market. He emphasised the significance of Continuous Inkjet (CIJ) technology, upcoming product launches, and investments in quality standards. He noted evolving customer expectations, service standards, and regulatory landscapes, underscoring the need for sustainability and regulations across industries. Kulkarni added, "Sustainability is a key factor in whatever we do today. The leaders then didn't look at sustainability, so now we had to have a lot of time focused on sustainability."

In the third conversation, Pallippuram Sajith, director of Stelda, shared insights on the future of packaging—automation, intelligent packaging, and sustainability. He emphasised the importance of adopting customer-centric strategies as Stelda’s plans to integrate its shipping cartons and filling businesses, introduce case packaging solutions, and prioritise reducing single-use plastics. Stelda, as Sajith shared, eliminates the need for plastic tapes, straps, and shrink wraps by providing an alternative glue-sealing solution for shipper cartons. These changes help businesses reduce operational costs, pilferage, and damage losses by over 30%.

In the fourth conversation of The Big Interview series, Milind Bhalerao, managing director, Becker India, spoke in great detail about Becker's investments, ever-expanding portfolio, the company's offerings for the packaging industry, the company's blueprint for 2025, and their six-month-old R&D training centre in India. Becker India aims to hit a 25% growth rate this year. Bhalerao states, "The focus in 2025 is investments and expanding our capabilities." Regarding the packaging industry trends, he says, "The food processing sector has now become one of the fastest growing industries even for us." While eliminating the consideration for degrowth, he emphasises that the company's only mantra remains: "Growth, growth and only growth."

In the fifth instalment of The Big Interview series, Bipin Panchal, chairman and managing director of Global Pet Industries, joined us from his factory office in Vasai. Known for their leadership in PET stretch blow moulding machines, Global Pet has become a significant name in the packaging machinery space. There was a detailed discussion about the blow moulding industry, where Panchal noted the shift from PVC and HDPE to PET bottles and the evolution of die-making and preform technologies. He made several key announcements and stated that Global Pet Industries is in the process of expanding its infrastructure and will soon be launching a new facility to enhance capacity to improve turnaround times. He also spoke about the company’s plans to introduce a next-gen automatic blow moulding machine, developed entirely in India, with an eye on export markets across Southeast Asia and Africa.

In the sixth instalment of The Big Interview series, Ravi Kiran, business director at Valco Melton, discussed the rising demand for advanced adhesive dispensing and quality inspection systems in India, expected to grow at a 15% CAGR by 2030. In the latest podcast, he shared how they began with a two-member team in 2018 and gradually scaled up to a 50-member team with a manufacturing and assembly facility in Pune. Kiran explained how they localised production to make systems more suitable and affordable for the Indian market, especially for sectors like corrugation, folding cartons and hygiene. He spoke about customer expectations around quality and service and how Valco Melton focuses on solving problems instead of just selling products. Kiran shared insights on Valco Melton’s 50% production expansion, focus on digital transformation, remote machine access, and sustainability. Speaking about what’s in store for Valco Melton, he said there would be more system integration, software, and smart inspection systems that add value beyond just glue dispensing.

In the seventh instalment of The Big Interview series, Samir Limaye, director at Wimco, reflected on the evolution of manufacturing from the company’s early days in Ambernath to the current operations in Bangalore, emphasising the importance of building customer trust and creating long-term value. There's a focus on the precision required for filling processes, with special attention to the shift in SKU sizes driven by changing consumer behaviours, particularly the impact of women in the workforce. Limaye highlighted the importance of automation and camera-based solutions to improve efficiency and reduce rejections. Sustainability also plays a key role, not just in materials but in the longevity and efficiency of machinery.

So far, seven podcasts have been published on WhatPackaging? YouTube channel, while the vision is to create a case study of 25 companies and industry A-listers discussing everything from the evolution of packaging and future trends to regulatory and sustainable considerations.

A milestone for CI Flexo manufacturing in India: Echaar unveils new press

Sai Deepthi P — Tue, 04 Feb 2025 16:46:00

“We are proud to be made in India,” says Echaar’s managing director Kirti Panchal in an interview with the WhatPackaging? team Echaar’s recently concluded Open House at its Ambernath manufacturing unit.

Panchal noted that the open house was a resounding success where Echaar showcased its latest advancements and provided a platform for its partners and potential customers to explore its cutting-edge solutions.

The second-generation Flexodelight series, showcased at the Open House, is equipped with advanced technologies that ensure consistent print quality while minimising energy usage.

Echaar’s USP is its 100% indigenous manufacturing, producing all components, including the critical CI drum, entirely in-house. This complete in-house production ensures strict quality control and delivers machines tailored to the Indian market while maintaining global standards of reliability.

Bridging the tech gap
When asked about addressing challenges like the learning curve required to operate CI Flexo printing machines, Panchal stated that Echaar is making CI Flexo printing more accessible and environmentally friendly. Echaar has collaborated with Claudio Maggio founder and ex director of Uteco) and one of the masters of flexo technology. This partnership, combined with Echaar’s understanding of the Indian market and operator psychology, has enabled the company to design a CI flexo press with a carbon fibre doctor chamber and the ability to notch up 500 metres on a variety of substrates.

Echaar has introduced several features to simplify operations, such as local switches for operators, enhanced HMI interfaces for real-time monitoring, and automated systems for tasks like ink management and machine cleaning. These innovations have not only reduced the reliance on manual intervention but also boosted the printability quotient. Panchal says, "The Indian packaging market is dominated by PE, as a sealant supportive layer for PET/PP based laminate structures. Mono-PE is a very small and not-so-easily accepted market. Echaar ensures one can print with PET, CPP, BOPP, BOPA on flexo." The key he says is, consistent quality and conformity to the required specifications.

One of the things, Echaar has leveraged is the inputs from its existing pool of customers. Panchal says, "As you are aware there is a learning curve for CI flexo operations. But thanks to our collaboration with partners for inks, plates and other consumables we have scored better than most. We are simplifying the process." In real terms this means the press has a quick changeover time (this is due to Easylock – a patented technology of Echaar’s Italian partner, CT Service SRLS). Also there is a full auto wash system, turrets on both the unwinder and rewinder, and an automatic reel lifter.

The future outlook
Panchal shared insights into the company’s expanding portfolio. In addition to the second-generation Flexo Delight series, Echaar is currently building four more CI Flexo machines, one stack press, and two solventless lamination machines. By the end of March, Echaar aims to have a total of six CI Flexo installations, two stack presses, and two solventless lamination machines—ensuring the Made in India marches into the double-digit installation count.

Echaar’s machines are designed to handle a wide range of materials, including BOPP, PET, LDPE, CPP, and paper. Also, Panchal shared that the tech team is working on solventless lamination machines capable of handling low-micron films, further expanding its capabilities in the packaging industry.

When it comes to energy efficiency, the company has incorporated features like hot air recirculation and ink cooling systems to optimise energy consumption.The company’s machines are also compatible with toluene-free and ketone-free solvent-based inks, which are more environmentally friendly.

Flexo trends
Echaar has observed a growing acceptance of CI Flexo printing among brands, particularly in segments like milk packaging, oil packaging, as well as hygiene products. The technology’s environmental benefits and cost efficiency have made it an attractive option for brands looking to adopt sustainable practices. Additionally, advancements in sleeve technology and high-density inks are expected to further bridge the gap between CI Flexo and gravure printing.

Panchal says, We can see the acceptance of flexo technology among brands for the reasons of sustainability. There is an equivalent and at times better output as compared to rotogravure."

The company is also exploring new possibilities in premiumisation and special effects, such as inline holographic printing and reverse matte coating. These innovations, combined with the ability to print at high resolutions (over 200 lpi), are opening up new opportunities for brands to differentiate their products in the market.

Looking ahead, Echaar is focused on scaling up its production capacity and exploring new markets, including exports. Meanwhile Kirti Panchal and the Echaar team return to the drawing board. The group is consistently working towards boosting the deck of offerings on their CI Flexo press. This covers downgauging, replacement of materials (lower density), TD reengineering, reduction in ink coverage along with other premiumisation ideas. Panchal says, "The press is one thing, but it's the new ideas and customisations which keeps us alert and vigilant."

Podcast with Vivek Chinoy, director, Electronics Devices Worldwide

WhatPackaging? Team — Tue, 22 Oct 2024 18:18:00

Podcast with Krishnan Viswanathan, director, Spheretech

WhatPackaging? Team — Tue, 22 Oct 2024 18:16:00

Podcast with Sunil Loharekar, national sales manager, Baumer India

WhatPackaging? Team — Tue, 22 Oct 2024 18:13:00

Podcast with Ravi Kiran Nimushakavi, director, Valco Melton

WhatPackaging? Team — Tue, 22 Oct 2024 18:09:00

Podcast with Anup Shah, director, Prismtech Packaging Solutions

WhatPackaging? Team — Tue, 22 Oct 2024 18:04:00

Podcast with Anthony D'souza, managing director, Mespack India

WhatPackaging? Team — Tue, 22 Oct 2024 17:59:00

Women to Watch: Meenakshi Sapru

Anushka Chourasia — Tue, 03 Sep 2024 17:31:00

Meenakshi Sapru began her career in 1995 with Bennett and Coleman in the production department, becoming the first woman in the history of the Times of India group to work in the newspaper production department. She played a key role in introducing color printing to the Times of India newspaper and in launching the Bombay Times.

Over her 26-year career, she has worked with organizations such as Bennett and Coleman, Yabasu Graphics, Xerox Corporation, and Hewlett Packard, drawing on her background in printing engineering and marketing. At Huhtamaki, Sapru has led sustainable initiatives like the Cup Collective and drove a 130% growth rate in Huhtamaki in India through a major business turnaround.

Sapru launched fiber lids for premium brands in India and led the first Cup Collective, which supports a circular economy. This project, in collaboration with major Quick Service Restaurants (QSRs), focuses on creating compostable products. She has also worked with regional pollution control boards to develop legislative frameworks for alternatives to Single-Use Plastics (SUP) in India. Her contributions were recognized when Huhtamaki was awarded "Supplier of the Year" by Herbalife.

Being a leader in a male-dominated industry, she said, “Success should not be gender-biased. As the industry evolves, diversity in the workplace has become critical. Women leaders are known to be more collaborative, empathetic, and inclusive, which can lead to a more engaged and productive workplace.” She added, “Female leaders bring structural and cultural differences to the table, which drive effective solutions. This creative standpoint and unique sense of awareness allows them to study and uncover the finer details that may go unmissed otherwise.”

Sapru has a strong interest in the evolving trends of the packaging industry. The initiatives she led have set a new standard in India. Her leadership has advanced Huhtamaki's sustainability goals and influenced industry standards, showing how focused efforts and practical practices can drive change.

(In this series, WhatPackaging? highlights the women who set new standards in our industry every day.)

Singh: Shaping a more sustainable packaging landscape

Ramu Ramanathan — Tue, 13 Jun 2023 11:59:00

Ramu Ramanathan (RR): Interesting to see so many conversations about packing tapes and sealing systems. Also, the return of pigments and resins. There seems to be a lot of ongoing research and exploration in that space. And finally, shipper crates and cartons. The readers of WhatPackaging? will be curious to know what your takeaways were?
Jay Singh (JS): Packaging regulations and directives are playing a pivotal role in driving transformative changes in the global packaging industry. These regulations are focused on addressing environmental concerns, promoting sustainability, and ensuring the safe handling and disposal of packaging materials. They are driving significant impacts on the industry, including the promotion of sustainable materials like biodegradables and the reduction of single-use plastics.

EPR regulations hold producers accountable for the entire packaging lifecycle, spurring the development of recyclable and reusable packaging. Recycling targets and standards are encouraging better infrastructure and increased recycling rates. Mandatory labeling and information requirements enhance consumer awareness and transparency. Harmonisation efforts are seeking global alignment, fostering a level playing field. Ultimately, these regulations are shaping a more sustainable packaging landscape worldwide, meeting environmental goals and consumer demands.

RR: There is the dilemma of packaging. A major global brand with significant presence in India has 10,000 SKUs and huge demands on usefulness and utility. How can packaging help?
JS: Considering the prevailing state and federal directives/regulations related to packaging and taking into account the influence of international counterparts, it is advisable to initiate packaging improvement and development efforts.

RR: What more should we be doing?
JS: It is crucial to acknowledge that Indian consumers have specific expectations regarding FMCG packaging, and India's supply chain and logistics environment possess unique characteristics. Adapting to the challenges inherent in consumer-facing aspects and supply chain requirements is of utmost importance.

RR: Is it possible to de-risk innovation at the research stage? Especially packaging innovation?
JS: De-risking packaging innovation at the research stage is possible through strategies such as comprehensive research, prototyping and testing, regulatory compliance, collaboration, supply chain considerations, intellectual property protection, and pilot programs with feedback.

These measures help align the innovation with market needs, evaluate functionality and compatibility, ensure regulatory compliance, leverage expertise, optimise the supply chain, safeguard intellectual property, and refine designs based on feedback. While these strategies reduce risks, it's important to remain adaptable and continuously learn to address unforeseen challenges.

RR: Transit losses due to damages and pilferage in transit probably do not receive the attention that it deserves. During your interventions for the research papers, I realised this is your area of specialisation.
JS: Distribution packaging plays a vital role in reducing losses and pilferage in the supply chain. My focus remains on assisting the industry in developing “fit-for-purpose” distribution packaging. This entails sustainability (packaging materials and designs) and validation of product-package systems via the optimal test methodologies for the anticipated distribution environment.

RR: Are you considering any initiatives in packaging that focus on addressing these issues?
JS: Strategies such as tamper-evident packaging, robust design, validation of packaging solutions through lab-based testing, tracking technologies, unique identifiers, transparent processes, collaboration with logistics providers, security measures, and employee training can mitigate risks.

Tamper-evident packaging deters unauthorised access, while robust design protects packages during transportation. Tracking technologies and unique identifiers enable real-time monitoring and easy identification. Transparent processes and collaboration ensure accountability. Video surveillance and security measures act as deterrents, and employee training enhances awareness. Implementing these strategies enhances security, traceability, and package integrity, reducing losses and pilferage in the supply chain.

RR: Secondary/tertiary packaging that helps transport the goods safely are probably not given the same importance as the primary, and is often seen as a 'cost item' by many. What will be your advice to the small and medium manufacturers and brands on changing this?
JS: Distribution packaging often doesn't receive the same level of attention as primary aka “romance” packaging. However, it plays a critical role in product protection during transit, efficient handling, shelf life preservation, branding and marketing support, regulatory compliance, sustainability promotion, supply chain optimisation, and customer experience enhancement.

Effective distribution packaging safeguards products, enables organised handling, attracts consumers, complies with regulations, promotes eco-friendly practices, improves logistics operations, and contributes to customer satisfaction. To optimise their supply chain, protect products, and create positive brand experiences, businesses should prioritise the development and implementation of effective distribution packaging strategies.

RR: How can recycling make business sense for it to become mainstream, and not remain a hobby project or ESG greenwashing?
JS: Several successful international packaging recycling businesses can serve as inspiration for India.

Singh: Smart packaging enables real-time tracking, interactive features, and product authentication

RR: Any success stories that you can share which may be relevant for India?
JS: Terracycle from the United States focuses on recycling hard-to-recycle waste materials, implementing innovative programs and partnerships. Ecoalf in Spain transforms recycled materials, including packaging, into high-quality fashion products. Loop, a global platform, offers products in reusable packaging, creating a closed-loop system to reduce waste. Tomra from Norway provides recycling solutions through reverse vending machines, encouraging consumer participation. Recup in Germany promotes reusable cups for takeaway beverages, reducing single-use plastic waste. While modifications may be needed, these examples demonstrate innovative approaches that can guide the development of packaging recycling businesses in India.

RR: As a business entrepreneur in India said, plastic recycling is not a money-making proposition. Is that the root cause of the problem?
JS: Plastic waste is a complex problem influenced by both behavioural and resource-related factors. Human behaviour, including consumption habits and improper disposal, contributes to the accumulation of plastic waste. Inadequate waste management infrastructure, limited recycling facilities, and a lack of resources further exacerbate the issue.

RR: More of a behavioural problem, and not a lack-of-resource problem?
JS: Tackling plastic waste requires a dual approach: promoting behavioural change through awareness campaigns and responsible consumer choices, and investing in infrastructure, recycling facilities, and innovative technologies. By combining these efforts, we can address the behavioural and resource-related challenges, reduce plastic consumption, and foster a circular economy to mitigate the impact of plastic waste.

RR: Is it important to create a plastic waste hierarchy? If we were to launch a coding system to cover the entire lifecycle of packaging from its constituents to its functions and its ability to recycle, what should it be?A coding system based on life cycle assessment (LCA) is the way to go. Do-able?
JS: A comprehensive and standardised coding system for packaging could include unique codes for material identification, product information, environmental impact, functional attributes, recycling instructions, and supply chain traceability. It would enable easy identification, informed consumer choices, sustainability promotion, appropriate packaging selection, proper recycling, and transparent supply chain management.

The system should be user-friendly and developed through collaboration with industry stakeholders, organisations, and regulatory bodies. Implementing a unified coding system would improve communication, consumer understanding, and efficient packaging management throughout its lifecycle. While fraught with challenges, any standardised initiative leads in the right direction.

RR: Do you think packaging is at times over-engineered?
JS: Yes, packaging is often over-engineered, with excessive complexity, materials, or features. Reasons include excessive protection, where the packaging has abundant materials and cushioning. Aesthetic considerations lead to over-designing, incorporating non-functional elements. Marketing objectives can result in overly complex packaging to stand out.

Regulatory compliance can also drive over-engineering, even if simpler options exist. Over-engineered packaging increases costs, resource consumption, waste generation, and environmental impact. Striking a balance between functionality, protection, aesthetics, and sustainability is crucial to avoid unnecessary complexity and ensure efficient packaging solutions.

RR: And finally, one technology trend that the packaging fraternity in this part of the world should be keeping an eye out for?
JS: The packaging industry should keep an eye on smart packaging. Technologies like RFID, NFC, QR codes, and sensors can improve inventory management, supply chain visibility, and consumer experiences. Smart packaging enables real-time tracking, interactive features, and product authentication. Adopting these technologies can bring efficiency, innovation, and convenience to the packaging industry.

The importance of packaging research

Packaging research is crucial for driving the future of the industry through innovation, sustainability, functionality, and addressing emerging challenges. It plays a significant role in shaping the industry by focusing on sustainable solutions, advanced materials and technologies, waste reduction and recycling, consumer engagement, supply chain optimisation, safety and regulatory compliance, and fostering collaboration and knowledge exchange.

By driving advancements in these areas, packaging research enables the development of efficient, environmentally conscious, and consumer-centric packaging solutions that meet evolving needs and contribute to a sustainable and efficient packaging ecosystem. Collaboration, partnerships, and knowledge exchange among stakeholders are essential for driving innovation and addressing complex challenges collectively.