Vijayshri Packaging Ltd is a fully integrated packaging company providing fibre-based packaging solutions to a demanding market. They specialise in offering the complete solutions which includes folding cartons and corrugated outers. In addition, the folding cartons include many upgrades such as windows, liners, and litho-lamination. Their attention to quality has allowed them to successfully partner with customers in the food processing, FMCG, pharmaceuticals manufacturing, and white goods industries. To meet the demands of their growing business, even amidst the COVID-19 pandemic, Vijayshri installed a new six-colour Lithrone G40 with coater UV offset press.
Strategically positioned in Indore, Madhya Pradesh, in central India, Vijayshri has built a world-class package printing factory with comprehensive integrated printing solutions. In 2021, Vijayshri achieved the milestone of 30 years in the industry. Today the company is one of the leaders in the Indian package printing industry, setting the benchmark for consistency in the market. Flawless work has been a significant part of its journey.
Strategic investments
Technology has been a crucial part of the Vijayshri story. Their biggest advancement was taken when the company decided to expand its operations and construct a new 25,000 sqm printing factory on a 43,000 sqm site. Operating from this facility, Vijayshri now provides comprehensive printing and packaging solutions, covering everything from design concept to delivery logistics, while maintaining strict quality control throughout every stage.
The company has also invested in automation and modernisation of its post press systems through investments in a new corrugator, litho laminators, two new die-cutters, and a new folder-gluer. Investing in the complete solution from press through postpress has given Vijayshri a competitive edge.
Vijayshri’s 10 acre site near Indore international airport.
Director’s perspective
Ayush Jain, Director of Vijayshri Packaging, speaks at length about the many features and benefits of the new Komori press and its impact on their business. “We have invested in automation and modernisation of our printing equipment. When we bought our first thermal CTP in 2005, we learned the meaning of consistency, reliability and quality. Over the years, we have improved our standards and always invested in reliable technology. The key to our growth is our ability to choose the right equipment at the right time.”
He continues, “The investment in the new Lithrone G40 is an important upgrade from conventional presses, achieved in partnership with Komori. With increased capacity of 36 million cartons per month, we are delivering a world-class experience for our customers. The plan to strategically invest in modernisation and cutting-edge technology began with a visit to Komori’s Tsukuba Plant in Japan even before the beginning of the COVID-19 pandemic. Our new Lithrone G40 is by far the biggest technological shift in the packaging arena in central India. Upscaling is a constant process, and now with Komori we have the tools and techniques to deliver on time without any compromise in quality. Our investment in this press certainly contributes to the modernisation of the factory and creates new markets and opportunities.”
Left to right: Rajendra Jain (Managing Director) and Pritesh Jain (Director), display the first print produced on the new six-colour Lithrone G40 with coater.
Increased productivity
Jain says, “Reduced press downtime and faster make-readies are the key reasons we upgraded our technology. We are happy with the performance of our Lithrone G40. We have seen a significant improvement in productivity as compared to our other machines. For the same jobs and inputs, we have seen a productivity jump of almost 45%. Another advantage we have discovered is the significant reduction of start-up waste. We now use up to 80% less paper for makeready thanks to KHS-AI, which has features such as Smart Sequence. Finally, the performance of the entire job is constantly monitored by the PDC-SX system that actively sends colour density and registration feedback to the press. The Lithrone G40 is our solution for enhancing productivity and delivering absolutely predictable quality.”
Left to right: Ayush Jain (Director), Pritesh Jain (Ayush’s uncle) and Prakher Jain (Pritesh’s son).
High-speed operation
The Lithrone G40 has a maximum operating speed of 16,500 sheets per hour, which increases output capacity. With the presets for the feeder and delivery, Vijayshri Packaging don’t have to rely on manual settings; operators just provide the sheet size and thickness, and all the settings are done automatically – from feeder through to side lay, printing units, and delivery joggers. Even when the machine is running at full speed, the quality of printing is not adversely affected.
The KHS-AI technology incorporates a self-learning function and automatically sets repeat jobs. This enables efficient paper changeover, which is crucial for work that includes many short-run orders for a variety of different products. KHS-AI stores all the information of previous jobs, making the operator’s job very easy. For repeat jobs, the ink settings have already been saved. Additionally for Vijayshri Packaging, the new Lithrone G40 can reproduce 90 to 95% of the special colours on repeat jobs.
PDC-SX automatically checks colour, front/back register, and image positioning on the paper and provides feedback to the press if any deviations are found. This system supports multiple jobs with differing printing conditions and ensures smooth operation. The colour bar measurement function in PDC-SX reduces any colour variation.
Finally, automatic functions such as blanket washing, roller cleaning, plate changing, and density control are tremendously effective in reducing the workload on the operators. The PQC operation console is user-friendly and comes with graphics that are easy to understand.
“Productivity, ease of use, and reduced paper consumption – the Lithrone G40 has it all,” concludes Jain.
