Transcript Sun Packaging Co. L.L.C., Our Journey so far…………. The Past…. Pioneer in Flexible Packaging Co.

Sun Packaging Co. L.L.C.,
Our Journey so far………….
The Past….
Pioneer in Flexible Packaging Co. in Oman.
The Company was incorporated in 1997
Started Commercial production in 1998
100% Locally owned Company with 4 individuals having
10%, and 2 Companies having the remaining share
Entry in Flexibles
Entry Level Investments / Market
knowledge
• One Rotogravure Printing Machine
• One Solvent less Laminating Machine
• One Slitting Machine
Over the next 3 years, Company added
• 2nd Solvent less Laminating Machine
• 2nd Slitting Machine
Installed capacity was 2000 tons
Build on the foundation
In 2004
• Need felt to add Capacity
• Company sufficiently skilled to move up the
technology chain
• Had a core group of employees who understood
Company culture
Addition of new Capacity
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2nd Rotogravure Printing Machine
1st Solvent based Laminating Machine
3rd Slitting Machine
Two Pouching Machines
Capacity doubles from 2000 tons to 4500 tons
With the expansion
• SPC was one of the pioneer supplier to consistently
supply Laminates for Hot filled Juice Pouches
a very aggressive medium
• SPC starts supplying to the Pet Food segment,
a large and growing market in Europe / USA
• SPC able to introduce Nylon based laminates that are
used extensively in Frozen foods
• SPC able to supply Standup and other Pouches, higher
value added products
Changing scenario
• Company became the 4th largest producer in the GCC, the
2nd Line capacity was filled up in 18 months
• Company had a Customer base of only 62, an indication of
high satisfaction level with existing users
• Exports were at 68% of capacity and increasing steadily,
evidence of Consistency in supply and service
Phase 3 - Consolidation
Company added new equipments:
• 3rd Rotogravure Printing Machine
• 4th Laminating machine – Dual Use with pattern Cold
Seal facility
• 4th Slitting Machine with facility for Micro slitting
and Large Reel winding
Installed capacity rose to 8000 tons
the work continues……
• Company able to utilize 50% of new capacity within 5 months of
installation
• Exports rise to 78% of capacity
• New Countries get added in the export list –
Russia Morocco Tunisia / Ukraine
• Company becomes the 3rd largest Converter in the Middle East
• Company also becomes the “Preferred Partner in New
Developments” with Exxon Mobil
• Company has developed Retort Pouches for Food applications in
combination with Rohm & Haas
• Company supplies alternate to replace Aluminum Foil in non
aggressive applications
Qualitative change over the years
• Wider Product option to clients– Surface printed option going
up to Retort pouches: Shift from commodity products to
complex products
• Greater stress on Employee Safety, Product Safety,
Sustainability / Factory Hygiene –laundry facilities / pest
control / individual lockers / washing facilities / Solvent
system
• Higher degrees of Certification – ISO 9000
• BRC / IOP Certified Company since 2009, rated Grade 1
• SEDEX approved – Audited for Ethical practices in work
place
Certification
Developments completed recently
• ERP system implemented along with Bar
coding of Stocks and Operations.
• Extrusion Coating & Lamination
• Upgrading of In house Blown Film
Capacity rises to 10,000 tons annually
Highlights of our journey
• Low Customer base – 114 customers, high customer
loyalty
• 100 % supplier of Laminates to P & G Middle east for
Shampoo sachets
• 100 % supplier of Laminates to Heinz
• 100 % supplier of Rainbow, Al Mudhish , Coast Milk
Powder laminates in the region
• BRC Rating – Grade 1
• SEDEX Ethical Audit successfully cleared
We specialise in
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Speciality Laminates where Client interested in Barrier properties of Laminates
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New Developments – rationalization of Costs OR new packaging techniques to
attract consumers – Twist Pet replacing PVC
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Complex Laminates with Foil or OPA or Metallic Inks or Matt Varnish
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Laminates with Metallised film but Window for product visualization
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Embossed Paper / Foil film for Butter / Soup cubes
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Cold Seal Laminates
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Low COF, high Impact resistance for Shaped Pasta
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Extrusion Lamination for Potato Chips
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Developments with Customers on Sustainability Projects – elimination of Foil in
Lids for Cups / Elimination of PE in Food trays for PET- PET sealing
Project
In Mauritius
Ongoing Expansion Project
in Mauritius
Flexible Packaging - New unit located in Mauritius
•Capacity – 2500 tons of Laminates in first phase
•Able to supply Mono layer & Laminates including
•Solvent less. Solvent based , Cold Seal
•Able to supply Ready made Pouches
Will make it possible to supply SADC & COMESA areas
on Duty Free basis
Current status in Mauritius
• Trial production currently in process
• Commercial Production –May-2014
Ongoing Expansion Project
PP Woven Sacks
Ongoing Expansion Project
Manufacture of PP Woven
Sacks
• Capacity : 3000 tons – 30 million bags of 50 kgs
• Location : Oman
Supply of:• Surface Printed Bags with / without handle
• Reverse Printed Bags
• Value added Bags for Product Promotion
PARTIAL LIST OF CUSTOMERS
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UNILEVER
H J HEINZ
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MC DONALD’S
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FARLEYS
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PROCTOR & GAMBLE
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NESTLE
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AHMED TEA
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SAVOLA GROUP
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NATIONAL BRANDS (SA)
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TIGER BRANDS (SA)
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NEW ZEALAND DIARY BOARD
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COLGATE PALMOLIVE (SA)
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CAMPINA
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ENGLISH BISCUITS (PAK)
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IRISH DOG FOOD
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ROYAL CANIN
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KRAFT FOODS
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TIFFANY
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HERSHEYS
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Client
Country
Product
Structure
:- NESTLE KIT KAT
:- UAE
:- CHOCOLATE
:- 30 MIC METBOPP-(COLD SEAL)
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Client
Country
Product
Structure
:- NESTLE TOLA
:- UAE
:- CHOCOLATE
:- BOPP / METBOPP-(COLD SEAL)
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Client
Country
Product
Structure
:- CADBURYS
:- EGYPT
:- CHOCOLATE
:- MIC Pearlised Bopp (Cold Seal)
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Client
Country
Product
Structure
:- HERSHEYS
:- UAE
:- CHOCOLATE
:- BOPP / MET BOPP ( low COF/ high OD)
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Client
Country
Product
Structure
:- MAATOUK
:- UAE
:- COFFEE
:- MATTPET / FOIL / PE
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Client
Country
Product
Structure
:- NATIONAL BRANDS
:- SOUTH AFRICA
:- BISCUITS
:- BOPP / Pearlised BOPP (Low SIT)
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Client
Country
Product
Structure
:- BRITANNIA
:- UAE
:- BISCUITS
:-BOPP / MM 488 (Mobil film) – High Gas barrier
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Client
Country
Product
Structure
:- ENGLISH BISCUIT MANUFACTURERS
:- PAKISTAN
:- BISCUITS
:- 12 PET / 18 MET BOPP
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Client
Country
Product
Structure
:- TIGER BRANDS
:- SOUTH AFRICA
:- ZIPPER POUCH (BREAKFAST CEREAL)
:- PET / PE
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Client
Country
Product
Structure
:- MCDONALDS
:- EGYPT
:- KETCHUP
:- PET / FOIL/ PET/PE – high bond / high shelf life
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Client
Country
Product
Structure
:- CAIRO FOODS
:- EGYPT
:- HEINZ KETCHUP
:- PET / FOIL / CPP ( 1 year shelf life)
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Client
Country
Product
Structure
:- AFIA INTERNATIONAL
:- EGYPT
:- OIL / GHEE
:- PET / PE
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Client
Country
Product
Structure
:- AATCO
:- SULTANATE OF OMAN
:- BURGER KING KETCH-UP
:- PET /FOIL / PET/ PE
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Client
Country
Product
Structure
:- UNILEVER
:- Egypt
:- Tomato paste
:- PET / FOIL/PET/PE
• Client
• Country
:- SDOBRY
:- RUSSIA
• Product
• Structure
:- MAYONNAISE
:- PET / PE ( converted to Standup Pouch with
Spout hence PE has to have special properties)
• Client
• Country
:- GRACE TEA
:- UKRAINE
• Product
• Structure
:- 2g TEA SACHETS
:- BOPP / MET BOPP ( high COF)
• Client
• Country
:- RENUKA
:- SRI LANKA
• Product
• Structure
:- COCONUT MILK POWDER
:- PET / FOIL / PE ( seal through contamination)
• Client
• Country
:- GRACE
:- Jamaica, West Indies
• Product
• Structure
:- COCONUT MILK POWDER
:-PET / FOIL / PE
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Client
Country
Product
Structure
:- UNILEVER
:- ALGERIA
:- DETERGENT POWDER
:- BOPP / (W0) PE
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Client
Country
Product
Structure
:- PROCTOR & GAMBLE
:- SAUDI ARABIA
:- SHAMPOO
:- PET / VM BOPP/ PE
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Client
Country
Product
Structure
:- RUSSIAN PET FOODS
:- RUSSIA
:- RETORT PET FOODS
:- PET /FOIL / NYLON / RETORT CPP
PRINTING MACHINES
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SCHIAVI PULSAR - WITH BOBST REGISTER CONTROL
-No. of Colours : Seven
-Max. printing width : 1030mm
-Printing substrates: OPP,METOPP,PET,OPA,WHITE CAVITATED OPP ,
WHITE OPAQUE OPP, PAPER
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ROTOMEC – ROTOPAK-3000-5 - WITH ELTROMAT REGISTER CONTROL
-No. of Colours : Eight
-Max. printing width : 1180mm
-Register cold seal for mono webs with Release lacquer coating
-Printing substrates: OPP, METOPP, PET,OPA, OPAQUE OPP,
WHITE CAVITATED OPP , PAPER & LLDPE
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SCHAVI ROTOMEC-RS 1200 - WITH BOBST S-5100 RESISTER CONTROL
-No. of Colours : Eight
-Max. printing width : 1200mm
-GAMA AUTO VISCOSITY CONTROL
-Register cold seal for mono webs with Release lacquer coating
-Printing substrates: BOPP,METOPP,PET,OPA,PAPE, OPP-OPAQUE
AND CAVITATED, PAPER
SUN PACKAGING COMPANY L.L.C.
LAMINATION MACHINES
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SCHIAVI ECO JUNIOR – 2NOS Year 1999 / 2000
Solvent less Lamination
-Max. printing width : 1200mm
-Substrates: BOPP, MET BOPP, NYLON,OPP
OPAQUE,CAVITATED,PET,ALU.FOIL,LLDPE,CPP,METCPP,PAPER
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NORD MECCANICA -2000 Super Combi Year 2003
Solvent less and Solvent based lamination
-Max. printing width : 1300mm
-Solvent less coating trolley with world mixer
-Rotogravure coating trolley- For solvent base and for water base
-Substrates: OPP, MET OPP, NYLON,CPP,METCPP,PET ALU.FOIL,
OPAQUE CAVITATED,OPAQUE,LLDPE,
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NORD MECCANICA -3000 Super Combi Year: 2007
-Max. printing width : 1315mm
-Solvent less coating trolley with world mixer
-Rotogravure coating trolley- For solvent base and for water base lamination
-Registered cold seal Trolley for lamination - Semi Flexo coating unit
-Substrates: OPP, MET OPP, NYLON,CPP,METCPP,PET ALU.FOIL,
OPAQUE CAVITATED, OPAQUE,LLDPE,
SUN PACKAGING COMPANY L.L.C.
SLITTING MACHINES
• SCHIAVI EASY SLIT -2 NOS Year 1998 /2000
-Max. printing width : 980mm / 1200mm
-Min. width : 50mm
-Substrates: OPP,PET,OPA,PE/FOIL LAMINATES AND MONO
WEBS.
• SP-ULTRA WITH QUICK LOCK SYSTEM Year 2003
-Max. printing width : 1400mm
-Min. width : 50mm
-Substrates: OPP,PET,OPA,CPP,PE,FOIL LAMINATES
• DCM PANTHERE Year 2007
-Max. printing width : 1450mm
-Min. width : 30mm
-Substrates: OPP,PET,CPP,OPA,PE/FOIL LAMINATES
AND MONO WEBS
SUN PACKAGING COMPANY L.L.C.
POUCHING MACHINES
Type of Pouches:
- 3 Side Seal
- Center Seal with / without Gusset
- 3 Side Seal with Zipper
- Stand Up Pouch with Zipper or K seal
- Quad Seal Pouch
- Stand up Pouch with Die Cut
- Pouches with Rope Handle / Euro slots / C Slots
- Pouches with 3 Finger Slots
SUN PACKAGING COMPANY L.L.C.
Multilayer Co-extrusion Blown
Film Line
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Width:- 1700 mm (max)
Thickness range :- 20mic TO 150 mic
Auto gauge & Auto Profile Control: PlastControl
Feeding System: Gravimetric system , Plastcontrol
Fully controlled IBC & OBC cooling system
SUN PACKAGING COMPANY L.L.C.
EXTRUSION COATING
LAMINATION MACHINE
• WIDTH :- 1250mm (MAX)
• THICKNESS :- 7gsm TO 40gsm
SUN PACKAGING COMPANY L.L.C.
Sun Packaging Co LLC
The journey continues------
THANK YOU