An interview from Mr.Krishnan Varadarajan Chairman, Vital Paper Products
Vital Paper Products Pvt. Ltd. provides packaging products and solutions throughout the value chain, enhancing the effectiveness, affordability and reliability of products.
Corrugman : Could we know more about Vital Paper Products?
Krishnan Varadarajan : Vital Paper Products Pvt Ltd. Operates as a fully owned subsidiary of Vital Solutions Pte Ltd, headquartered in Singapore. In 2012, we inaugurated two cutting edge automated paper conversion plants located in Sri City, in the Greater Chennai region of South India.
Our SEZ (Special Economic Zone) facility is dedicated to producing customized office and scholastic stationery for export markets. Meanwhile, our DTZ (Domestic Tariff Zone) facility focuses on manufacturing corrugated packaging products, equipped with advanced features like four-color printing, rotary die-cutting, and slotting in various formats. We supply our packaging products across India, prioritizing efficiency, affordability, reliability, and product innovation.
CM : What are your company’s principles, mission & vision?
KV : Our Principle: At Vital Paper Products Pvt Ltd, we are dedicated to delivering exceptional quality and reliability in all our products. Our focus is on exceeding customer expectations through tailored solutions and outstanding service. We leverage cutting-edge technology and innovative practices to maintain industry leadership while committing to environmentally responsible and sustainable practices.
Integrity and transparency guide our operations, ensuring ethical standards and trust. We prioritize efficiency, optimizing processes for productivity and cost-effectiveness, and foster a collaborative and safe work environment. Adaptability is key as we stay responsive to market changes, and we actively engage in community support and social responsibility.
Our Vision: To be a leader in the packaging industry, and be known for our commitment to quality, sustainability, and customer satisfaction.
Our Mission: To provide high-quality products that meet the needs of our customers while promoting sustainability and innovation.
CM : What are all the type of cartons manufactured by Vital Packaging?
KV : We manufacture a wide range of corrugated products, including inner boards, sheets, and cartons. In an overview, the following:
- Regular Slotted Cartons (RSC)
- HRSC & Overflap Flexo Printed Cartons
- Heavy Duty Cartons
- Die-Cut & Pizza Box Type Offset Printed Cartons
- Duplex Cartons
- Lid & Bottom Partitioned Boxes
CM : Do you produce laminated carton/coated carton which ensures for oil & waterproof applications?
KV: Yes, we do produce laminated and coated cartons designed for oil and waterproof applications. We offer customized and sustainable solutions tailored to meet specific user needs and ensure optimal performance.
CM : Please tell us more about your die-cut boxes and customized cartons.
KV : Our die-cut boxes and customized cartons are crafted using
both inline rotary die cutters and offline platen die cutters, allowing us to provide a wide variety of carton styles and configurations.
Inline Rotary Die Cutters: These machines offer high-speed, continuous cutting for large volumes, making them ideal for consistent and efficient production of standard die-cut boxes.
Offline Platen Die Cutters: These machines provide precise and flexible cutting for more complex and custom designs, accommodating intricate shapes and smaller production runs.
By leveraging both technologies, we can deliver diverse options, from simple to highly customized cartons, ensuring that we meet specific requirements and preferences for various applications.
CM : What is the maximum ply, length & width of cartons can be manufactured by your unit?
KV : Maximum ply – 5 ply Maximum width – 1800 mm Maximum length – 3600 mm
CM : Technical features of your manufacturing plant such as capacity, facilities, machinery etc.?
KV : Technical Features of Our Manufacturing Plant:
BHS ECO-Line (Germany):
- Capacity: Automated plant with a monthly installed capacity of 3,000 MT.
- Ply Configurations: Supports 3, 4, and 5-ply configurations.
- Maximum Dimensions: Width: 180 cm; Length: 360 cm.
- Flute Types: A, B, C, E, with combined options like AB, BC, AE, AC, and EB.
Four-Color Flexo Printing Machine:
- Features: Equipped with a ceramic anilox roller, vacuum feeder, slotter, and rotary die cutter.
- Size: 1.2 x 2.4 meters.
Two-Color Flexo Printing Machine:
- Size: 1.6 x 3.2 meters.
Automated Glue Kitchen and Flute Laminator/Folder Gluer:
- Function: Ensures precise and consistent application of glue, enhancing product quality.
Automated Conveyor System:
- Function: Efficiently handles board movement throughout the production process, optimizing workflow.
Double-Head Stitcher and Auto Gluing Machine:
- Features: Designed for secure and efficient stitching and gluing, ensuring the durability and reliability of our cartons.
CM : How important is the QC for a carton box manufacturing company and what about your testing facilities?
KV : Quality control (QC) is crucial in carton box manufacturing to ensure that every product meets stringent standards and performs reliably in various applications. At our company, we prioritize rigorous QC practices throughout the production process to deliver high-quality cartons.
Our testing facilities are equipped with a comprehensive range of procedures:
- Moisture Testing: Prevents warping and maintains structural integrity.
- Compression Tests: Includes Box Compression Test (BCT), Edge Crush Test (ECT), Flat Crush Test (FCT), and Ring Crush Test (RCT) to evaluate strength.
- Bursting Strength Test: Ensures durability during handling and transportation.
- Drop Test: Verifies product safety during shipping and handling.
- Grammage (GSM) Testing: Ensures consistent quality and strength.
- COBB Test: Maintains product integrity under exposure to humidity.
- Viscosity Test (Glue/Inks): Assesses bonding strength and print quality.
- Caliper (Thickness) Test: Ensures consistency in manufacturing.
- Compliance with TAPPI Standards: Guarantees consistent quality and performance.
- Barcode Scanning: Ensures accuracy and readability for effective inventory tracking and product identification.
These procedures enable us to provide cartons that meet the highest standards of quality, ensuring they perform reliably and meet our customer’s needs.
CM : May we know about your environmental management policies?
KV : At Vital Paper Products Pvt Ltd, we are dedicated to sustainable manufacturing practices with a focus on minimizing our environmental impact through:
- Responsible Sourcing: Ensuring that our raw materials are ethically and sustainably sourced.
- Energy Efficiency: Implementing energy-saving measures and technologies to reduce consumption.
- Waste Reduction: Actively minimizing waste through efficient production processes and recycling initiatives.
- Water Conservation & Emissions Control: Managing water use responsibly and controlling emissions to protect the environment.
These policies reflect our commitment to environmental stewardship and sustainable practices in all aspects of our operations.
We adhere to all environmental regulations and are committed to continually improving our processes to support a greener future. Our proactive approach ensures that we not only comply with current standards but also seek innovative ways to enhance our environmental performance.
CM : Do you face any challenges in the market?
KV : Yes, we do face multiple challenges in the market. One significant issue is the scarcity of paper waste and pulp, which is leading to frequent increases in paper prices. This situation puts cost pressure on the supply chain and makes it difficult for the packaging industry to remain competitive.
CM : Your company has any other group companies?
KV : Yes, Vital Solutions Pte Ltd, based in Singapore, serves as our headquarters. It is a leading global entity in the paper industry, specializing in the production and distribution of a wide range of paper products, including newsprint, uncoated woodfree paper, photocopy paper, bank and manifold paper, lightweight coated paper, and duplex boards. With a strong international presence, Vital Solutions Pte Ltd caters to key markets across Africa, Europe, Australia, Southeast Asia, the Middle East, the USA, Brazil, and the Indian Subcontinent.
CM : What is your business expansions plans in India?
KV : We are looking at a multi-pronged approach including,
- Plant Expansion: We are increasing our facility size from 100,000 sq. ft. to 175,000 sq. ft. to production capacity and address growing market demands.
- Strategic Warehousing Growth: We are enhancing our warehousing capabilities by establishing conversion plants in key locations such as Hyderabad, Chennai, and other strategic locations.
- Product Line Innovation: We plan to introduce laminated boxes with offset printing and auto die-cut capabilities to expand our product offerings and meet premium packaging needs.
- Technological Advancements: We are investing in advanced line balancing machinery that integrates printing, gluing, and stitching functions to ensure seamless and efficient production.
These initiatives reflect our commitment to expansion, innovation, and technological advancement, driving future growth and operational excellence.
CM : How are the technology advancements of corrugation industry in India?
KV : Traditionally, the corrugated packaging industry in India has been fragmented and dominated by small-scale operations. However, over the past two decades, industrial development and economic reforms have led to significant advancements. Many larger players have invested in high-tech machinery, which has allowed them to produce higher quality cartons that meet increasingly stringent customer requirements for both quality and runnability. This shift reflects the industry’s adaptation to modern standards and enhanced capabilities.
CM : How do you forecast the growth of Indian corrugation Industry in the near future?
KV : The growth of the Indian corrugation industry is closely tied to global industrial expansion. Additionally, there is a significant push in India to replace single-use plastics with more sustainable materials like corrugated packaging. This shift is driving double-digit growth in the Indian market, outpacing the growth rates seen in more developed regions.
CM : What is the actual scenario of paper sustainability in India and how to make the paper more sustainable?
KV : In India, the paper industry heavily relies on paper waste as the primary feedstock rather than virgin raw materials. However, the waste collection system is not very advanced, creating challenges in sourcing sufficient local paper waste. As a result, many mills are compelled to import paper waste from other parts of the world, a situation further complicated by global supply disruptions, such as the ongoing Red Sea crisis. This uncertainty has led to reduced capacity and difficulties in meeting customer demands on time.
To enhance paper sustainability, India could focus on improving waste collection and recycling infrastructure, investing in more efficient sorting technologies, and promoting the use of sustainable raw materials. Additionally, fostering innovation in recycling processes and encouraging responsible consumption practices can further support the sustainability of the paper industry.
“We offer a comprehensive range of paper products and customized manufacturing solutions, spanning everything from school and office stationery to tailored packaging solutions”
