PACKAGING
‘First Time Right’
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Fair & Lovely, a household name in fairness creams across India, is a recent addition to its portfolio. The pack’s soft vignettes are achieved with surface lamination and Offset printing.
Meet ITC Paper Packaging—India’s leading packaging player driven by its burgeoning internal demand.
The Division, which was set up in 1925 as a strategic backward integration for ITC’s Cigarettes business, is today India’s most sophisticated packaging house. State-of-the-art technology, world-class quality and a highly skilled and dedicated team have combined to position ITC as the first-choice supplier of high value added packaging.
After the amalgamation of the erstwhile ITC Bhadrachalam Paperboards Limited with ITC, ITC has now integrated its Paperboard and Specialty Papers businesses into its newly created Paperboards & Specialty Papers Division (PSPD), to harness strategic and operational synergies.
ITC is one of the world’s most modern and contemporary manufacturers of packaging boards. With a manufacturing capacity of over 200,000 tons per year, the Paperboards business is the Indian market leader across all carton-consuming segments including cigarettes, foods, beverages, pharma, personal care & toiletries, durables and match shells.
The mill facilities have been continuously upgraded to achieve internationally benchmarked quality standards and operational efficiencies. In 1998, the Paperboards business commissioned a new production line for coated boards, incorporating a coated board machine of 120,000 tpa and finishing equipment sourced from internationally renowned suppliers. A major project to modernize the pulp mill to produce 100,000 tpa of Elemental Chlorine Free (ECF) quality pulp has been completed.
The Division also produces quality printing & writing papers, eco-friendly papers, photocopier papers.
Specialized premium paperboards from the Division include the ‘Cyber Cypak’ range of folding box boards for high value cartons, the ‘Pearl Graphik’ high value SBS boards for greeting cards and covers, the ‘Indolux’ high gloss cast coated papers and boards, the value-for-money ‘Ecoviron’ range of recycled white lined chip boards for everyday products. The Division is the market leader in Carton Boards & Liquid Packaging Boards. ITC’s Paperboard products are used by almost all well-known FMCG brands in India.
ITC is the largest exporter of coated boards from India. More than 25 per cent of the coated boards made by the Company are sold in international markets including Malaysia, Sri Lanka, Bangladesh, Iran, Australia, UAE, Saudi Arabia, Singapore and Hong Kong.
ITC has set up India’s first world-class plant for the manufacture of premium Cast Coated Boards which meet highly sophisticated packaging and printing requirements. ITC also pioneered the development of Liquid Packaging Boards and baseboard for Plasterboards. These continuous product development efforts have reinforced and strengthened ITC’s market leadership in the Paperboards business.
A strong customer focus is a basic article of faith with the Paperboards business. The ‘Total Quality Assurance’ concept is practiced at every stage of manufacture. State-of-the-art on-line process control and scanning systems deliver internationally accepted quality standards.
In a farsighted corporate effort to improve ITC’s global competitiveness on the basis of the availability of fibre, ITC launched a major social and farm forestry program with clonal plantations. The program also consistently enriches the environment. Under this green initiative, the Division supplies millions of clonal saplings every year to farmers in Andhra Pradesh and obtains a part of its raw materials from these plantations.
The Division initiated bio-technological research in 1989 to develop and propagate genetically superior, high-yielding, disease-resistant clones. Large scale plantations have been raised on over 10,000 hectares of lands belonging to the farming community with 72 high yielding varieties of eucalyptus, popularly called ‘Bhadrachalam’ clones.
The yield from these ‘Bhadrachalam’ clones is thrice that of the normal seed route plantations. The Company disseminates its research knowhow on best agricultural practices to farmers through free consultancy services.
Specialty
Papers
ITC is the premier manufacturer of Specialty Papers in India, with a
diversified product range. ITC’s Specialty papers are used in
the manufacture of cigarettes, decorative laminates, electrical equipment,
fireworks and automotive filters. They are also used for fine printing,
packaging and carbonising.
The Division pioneered the manufacture of Specialty Papers for the Indian
cigarette industry in 1949. It currently offers a comprehensive range
of Cigarette Tissues, Plug Wrap, Tipping Base, printed tipping papers
and Metallising Base.
Specific customer needs are the focal point for the Specialty Papers
mill of the Division at Chandrahati, West Bengal. The mill reconfigures
systems and processes to meet specific customer needs. Quality control
processes at the mill are designed to ensure consistent high quality
at every stage of manufacture. On-line monitoring and documentation
of production parameters are carried out for continuous correction and
updation of quality standards.
A Product Development Team ensures Total Quality Management (TQM) in
all operations. The TQM group coordinates with the marketing, production
and research teams to ensure international standards in products and
services. It evolves long-term product development solutions on the
basis of customer specifications and market trends.
The Company has significant and sophisticated capabilities in product
development and research in pulp and paper. ITC has collaborated with
the United Nations Development Program (UNDP) and the Government of
India on research programs on the manufacture of high quality pulp.
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ITC
is the premier manufacturer of Specialty Papers in India, with
a diversified product range. ITC’s Specialty papers are
used in the manufacture of cigarettes, decorative laminates, electrical
equipment, fireworks and automotive filters. They are also used
for fine printing, packaging and carbonising |
The Division exports cigarette tissues and decorative laminates to Iran, Indonesia, Philippines, Sri Lanka, Nepal, Bhutan and Bangladesh.
Value-Added
Packaging
The Division supplies value-added packaging to the Company’s Cigarettes
business. Its client list includes several well-known national and international
companies like British American Tobacco, VST Industries, Surya Nepal
Private Limited, UB Group, Shaw Wallace, Seagrams, Allied Domecq, Whyte
& Mackay, Hindustan Lever, Tata Tetley and Nestle.
With two ISO 9002 certified & ISO 14001 certified packaging factories
at Tiruvottiyur near Chennai and Munger in Bihar, the Company offers
a comprehensive product range in packaging : flip-top boxes, cardboard
outers, shells and slides, softcup and strap labels, bundle wraps, flap
boxes, inner frames, coupon inserts and folding cartons.
ITC occupies a leadership position in cigarette and liquor packaging
in India. It supplies packaging to cover 70 billion cigarette a year
domestically, and supplies packaging for 15 billion cigarette
sticks
a year for the export market. It is the largest supplier of liquor mono
cartons in the country and its service range spans all carton sizes,
from 180 millilitres to 1 litre.
ITC has enhanced the value of some of the world’s most favoured
product brands with superior look-and-feel packaging, using the best
raw materials and process combinations, and an in-house pre-press Design
Centre.
A Product Introduction Process team pioneers packaging innovations.
The team uses a unique process to pilot the client’s packaging
through its manufacturing system. Specifications are evolved based on
the clients’ needs. Corresponding to the specifications, a variety
of packaging solutions is then generated.
ITC-PPD, offers packaging solutions for cigarettes, liquor, food &
beverages and personal products.— your complete guide to ‘value
for money’ packaging solutions.
At ITC-PPD the product is pampered with a minimum of three pack options.
“We justify your packaging investment with the best raw materials,
advanced manufacturing technologies, in-process quality measures and
reliable delivery schedules”, says Ashish De, Vice-President (Technical)
paperboards and specialty papers division.
Company’s packages have won several awards and propelled many
products to leadership in Asia, South Africa and the Middle East. Today,
the company is one of South Asia’s largest paper and paperboard
converters with a conversion of over 30,000 metric tons per annum.
South
Asia’s Leading Cigarette Packager
Company offers the right package design, uses innovative methods of
execution, to ensure perfect package quality and assure prompt delivery.
The experts behind some of world’s finest cigarette packaging,
ITC has contributed to the enhanced visual appeal and pack performance
for leading brands like Benson & Hedges, Lucky Strike, Hollywood,
Embassy, John Player’s Gold Leaf, Wills, Sportsman and Gold Flake.
Today, it is a trusted company supplying packaging for over 70 billion
cigarette sticks nationally and twelve billion internationally.
Company’s packs run on high-speed packers like GDX2, CME, Focke,
Schmermund and Molins. The company offers a comprehensive product range
which includes flip-top boxes, cardbord outers, shells and slides, softcup
and strap labels, bundle wraps, flap boxes, inner frames and coupon
inserts.
Maximum
Visual Impact and Functionality for Your Package
At ITC-PPD, the package is made from the best materials in tried and
tested processes, and benchmarked with international quality standards.
The largest supplier of liquor mono cartons in India, company’s
service range spans all carton sizes, from 180 millilitres to 1 litre.
At
ITC-PPD requirements for a variety of folding cartons is satisfied.
Our drive to offer increasingly better quality packaging is powered
by acquisition of cutting-edge technologies. The company operates
flat bed and rotary die cutting machines for punching your cartons,
enabling them to run efficiently on high-speed packing machines |
ITC PPD endowed some of the world’s favoured brands like Bagpiper, 100 Pipers, Black and White, Teacher’s 50, Passport and Royal Challenge with superior visual and functional merit.
In recognition of its packaging standards, company received the WorldStar award for McDowell’s Festival Twin Pack in 1990. Royal Velvet and Passport whisky cartons were awarded in 1998.
Passport
WorldStar Award 1998
Passport whisky is one of Seagram’s popular international brands.
The requirement: Matching Passport’s international pack
quality in the Indian market.
When Seagrams introduced Passport scotch whisky in India, they required
packaging that would exactly match their international pack standards.
In us, they found a partner who could meet their demanding packaging
requirements.
The challenge: Achieving visual and functional excellence
Printing the ‘coat of arms’ to the right finish: The Passport
carton’s complex ‘coat of arms’ print was achieved
with careful foil stamping and embossing. The tolerances on embossing
and foil stamping were extremely tight.
Arriving at the right carton formation: The carton formation on imported
high grammage (465 gsm.) board induced high spring back action during
gluing. The company devised a method where the board was retained and
the spring back problem solved. There was no compromise on the pack’s
functional quality.
From
Bulk Packaging to Cartons
At ITC-PPD requirements for a variety of folding cartons is satisfied.
Our drive to offer increasingly better quality packaging is powered
by acquisition of cutting-edge technologies. The company operates flat
bed and rotary die cutting machines for punching your cartons, enabling
them to run efficiently on high-speed packing machines.
Small and medium runs are accommodated on the strength of the company's
state-of-the-art Offset printing machines.
Leverage
the company's knowledge and experience in packaging to get a well configured
package for your product. Quality of visual design is assured by the
presence of the company's pre-press Design Centre and latest packaging
technologies. The company also enhances package functionality by using
the best raw materials and facilitating process combinations.
Fair & Lovely, a household name in fairness creams across India,
is a recent addition to the company's portfolio. The pack’s soft
vignettes are achieved with surface lamination and Offset printing.
Packaging
Products ‘First Time Right’
The company's Product Introduction Process (PIP) team has been instituted
to focus on new packaging innovations. This multifaceted six-member
team has expertise across varied fields like engineering, marketing,
printing technology and conversion.
PIP follows a unique process of piloting your package through the company's
manufacturing system. This process guarantees you a visually and functionally
superior package, first time round.
Modus operandi: Understanding your needs; Development
needs specification ; The PIP team will first understand your packaging
requirements and specifications, and then analyse it to chalk out packaging
possibilities.
Harnessing expertise to offer varied configurations:
Package options The company's team will devise carton configurations
best suited to your requirements, translating your needs into features.
Using the expertise and experience of the PIP team members, each of
who possess a unique skill, varied package options will be arrived at.
The cost for each option will be calculated. Also, your package options
will be benchmarked against international standards of packaging.
Communication with the team and quick in-process feedback is made easy
by the presence of ISDN lines and Lotus Notes.
Choosing your packaging solution: Once the options folder is ready,
you can choose the packaging solution you prefer from the wide range
offered. The PIP team tests your package on the company's manufacturing
system simulating your factory conditions, ensuring package performance
before approval.
The Design Centre Deploying technology to realise packaging innovations.
The company's PIP team receives invaluable assistance in developing
innovative packaging from the company's Design Centre.
Housed with high-end Silicon Graphics workstations, image setters and
Macs, the Design Centre plays a crucial role in building robust designs
for manufacture.
The
Zero Defect Campaign
Improve your package’s visual and functional quality.
At ITC-PPD quality is built into your package from configuration to
final inspection. An in-process operator self check, the company's zero
defect campaign enhances key attributes of package quality.
Zero defect scores are processed through proprietory software and drive
quality improvement projects.
Best-in-class equipment: Quality enablers for your package: The company's
laboratories are fitted with grammage and caliper testers, and Metlabalance
digital micrometer. Other sophisticated test equipment ensure high quality
by testing your package in simulated environmental, transportation and
storage conditions.
The company also possesses the sophisticated Maxtrascan, which is capable
of measuring linear dimensions, angles, embossed surfaces and cavities
upto 1 micron.
All the machines on the shop floor are fitted with quality control equipment
and have feedback mechanisms through which quality is monitored in-process.
The company's equipment facilitate quality checking in high-speed packing
environments.
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Choosing your
packaging solution: Once the options folder is ready, you can
choose the packaging solution you prefer from the wide range offered.
The PIP team tests your package on the company's manufacturing
system simulating your factory conditions, ensuring package performance
before approval
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Quality certifications: ITC-PPD is the first Indian company to be awarded
the International Quality Rating System (IQRS) Level 6. ISO 9002 certification
for both Chennai and Munger factories in India.
Advanced quality tests How the company ensures visual and functional
quality for your package: The company enhances visual appeal with spectro-photometric
colour measurement tests and Q 100 online imaging. Cigarette packaging
Visual quality
Functional quality
The company's sophisticated tests for functionality include dynamic
crease resistance, coefficient of friction and solvent residue.
Packaging for liquor, food & beverages and personal products: Visual
quality
Your package undergoes spectro-photometric colour measurement tests
to achieve a high level of visual quality.
Functional quality
Functionality is ensured through rub resistance test & peel test
for laminated products.
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CASE
STUDY |
The
Wills Classic Project Wills Classic is ITC’s premium cigarette brand available across India in four varieties - Full Flavour, Milds, Ultra Milds and Menthol. Requirement for Wills Classic: Packaging for the modern consumer. ITC was in search of contemporary packaging to enhance the brand’s positioning. A solution was needed for the complete Wills Classic range, from Full Flavour to Ultra Milds. Product Introduction Process (PIP) team was brought in to analyse the need, develop a modern packaging solution and provide a plan for smooth execution. Key Factors Affecting Execution: Pack sizes, graphic designs and tooling combinations - Four pack size variants: 20’s flip-top, 10’s flip-top and corresponding outers. - Four distinct graphic designs: For the Full flavour, Milds, Ultra Milds and Menthol brand extensions. - 16 tooling combinations: Tooling equipment for the project comprised 80 Gravure cylinders, Rotary and Flatbed embossing, cutting and creasing dies. Process roll-out Co-ordinating between varied processes and decision makers The project was supervised at every level. Several meetings were held in Germany and India where progress was critically reviewed. Here are some of the crucial stages in the making of Wills Classic packages. Perfect ink matching Finding the right ink for Wills Classic involved multiple interactions with SICPA, the company's ink suppliers, and Goerz, the company's print cylinder suppliers. The ink was tested in SICPA’s laboratory, Goerz’s proofing press and on the company's Bobst-Lemanic machines. Packaging for Classic was hitherto sourced from a Singapore based company that manufactured its own proprietary inks. Sourcing the world’s finest tooling: Extensive networking with Goerz, the company's print cylinder suppliers and Saurrersig, the company's rotary embossing cylinder suppliers, helped achieve high quality embossing. Specialized quality assurance procedures: The packages were put through advanced quality tests to make sure visual and functional performance parameters like colour, rub resistance and crease resistance matched international standards. Devoid of any solvent residue, the packages received positive test certifications affirming their high quality. Effective testing: The packages passed machine runnability trials using unprinted packs before actual bulk manufacture at ITC’s factory in Bangalore, India. ‘First time right’ for Wills Classic: Expert execution from the Product Introduction Process team The PIP team’s project monitoring and communication skills successfully turned a complex assignment into a simple one. Strong teamwork saw PIP through the challenging development phase and helped build Wills Classic a ‘first time right’ packaging solution. The new Wills Classic packages have earned us the confidence of other clients in being able to handle similar projects. The company has translated the experience and knowledge gained from this project to several others. John
Player’s Gold Leaf |
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