A Kodak Achieve CTP success story that speaks of the device’s robust efficiency and the customer’s prowess in producing Packaging.
BK Print & Pack not only standardized its plate processing through a Kodak Achieve CTP they installed 5 years ago but has also been an innovative packaging producer to put itself on a higher pedestal of growth. Catering to the high-end MNC customers, the ISO certified firm has brought out its own ways to remain at the top – be it developing a sustainable packaging solution by replacing thermocol for its clients or the rare feat of using their process-free plates for re-prints.
BK Print & Pack is a pioneer packaging firm based out of Haridwar in Uttrakhand. Providing packaging solutions and delivering value through sustainable product packaging to top brands and MNCs, the firm has enabled brands represent perfectly through packaging, have a unique identity and appeal to the target audience. Housing among the best infrastructures with state-of-the-art technologies BK has helped customers realize the true potential of their brand by setting up a story through their packaging.
BK manufactures a wide range of products including point of purchase displays, designed for convenience and vital advertising, to the heavy duty corrugated packing, for international transport or storage for a number of leading brand names. The products by the ISO 9001:2015 certified BK Print & Pack include Multicolor Mono as well as Outer Cartons, Printed or Unprinted Flute, Lamination including Laminated Boxes, UV or Varnish or Texture or PET MET based Coating etc. They are known for their quality, on time delivery, innovative and modern products as well as customized solutions enabled by the latest technology all under one roof.
Strong management, which is the key driving force of the successful BK Print & Pack, is chiefly led by the highly experienced partners Sandeep Singla and S.K. Jindal.
PRESSIdeas had a visit to their facility to bring you the story of their success.
BK Print & Pack is a one stop shop for packaging solutions that have a wide range from mono to flute to 5-ply cartons, to the recently added corrugated along with other products. The firm with in-house capability of UV, MET PET coating, varnish, lamination and textured coatings etc. has recently added an automated facility at Dera Bassi near Chandigarh.
Around 5 years ago, with no previous experience with CTP equipment, BK Print & Pack had been doing its plates through conventional film processing workflow. When working in Haridwar, BK Print Pack had to get their plates procured from outside. Conventionally done, the plates would come from Meerut, Delhi or Chandigarh since there was no imaging service provider nearby. It would cost them a lot of time and money, which was worse should the plates have some technical or quality issues. For quite some time they had been looking for a more practical solution for their plates. They visited the Print Pack India exhibition of 2017 and happened to meet Aarushi Agency’s team to explore CTP possibilities. They have been ably guided by Mr. Ashish Sharma of Aarushi Agencies all through these years right from the first day. “We didn’t give a second thought when it came to procuring a CTP from Insight,” says Sandeep Singla. “Ashish Ji was there to guide us in this professional and futuristic decision and we were looking for a way to eliminate all the hassles of plate procurement,” he adds.
They considered various options including the one from Technova which came with processor. After discussing the pros and cons vis-à-vis Kodak Achieve, they finalized and soon installed the Kodak device in 2017 itself. “Ashish Ji and Natesh Puri, National Manager – Plates & Chemical and Packaging segment at Eastman Kodak Company explained us the capabilities of Achieve along with processless plates. We evaluated the available options on various parameters and found Achieve best suiting our requirements. The advantages of processless plates were just unbeatable. They are not only chemical free, but are also free from hassles of unnecessary preparation steps, had better quality and also meant an environmentally friendlier technology,” says S.K. Jindal, Sandeep’s partner. For Sandeep it was also an opportunity to go for the latest technology and upgrade to the latest to be the best equipped service provider in the market. It indeed turned out that way – BK Print Pack is the first packaging printer in the country to have a complete process-free plate production from the Kodak stable. As for production volumes, they have just quadrupled their plate consumption – starting from 500 plates to about 2000 plates per month presently.
Environment friendliness is one of the key traits of BK Print & Pack; they have preferred environment friendlier processes and solutions over popularly available ones even if they came with a higher price tag. They have a large high-end customer base which was always ready for eco-friendlier products and these customers have more than often chosen the eco-friendly products over those which were less so. “We have MNC customers in our clientele and they have inspired us towards eco-friendlier solutions, which are our preference anyway,” says Sandeep. On its part, BK Print & Pack has replaced the use of thermocol with pulp material in packaging for two of their key clients, Philips and Havells. This feat was achieved working with the clients and developing the right product through BK’s in-house R&D.
In recent few years many cost reduction methods have been explored and followed in the industry to make the processes more efficient and products more viable. Sandeep cites instances when their same client has shifted one product from MET PET or UV based processes to conventional offset and vice-versa. This has been innovatively provided by BK Print & Pack by understanding the customers’ needs and putting all efforts behind it to bring out the best alternative at the best price for them,” says Sandeep.
Deciding on the Kodak Achieve CTP
Catering to the MNC customers, BK Print Pack was looking for a solution that can bring consistent dot reproduction and print quality. Since neither a film based workflow nor plates procured from trade shops were feasible, the company decided to work towards strengthening their pre-press through standardizing their plate process and start from that point towards their growth targets. Another factor under consideration was the cost of procurement and running the equipment and eventually the ROI of the set-up. The Kodak Achieve investment won over the conventional device (with processor) for its clear saving on chemistry and other variables. One important deciding factor, of course, was the space saving advantage of the Kodak CTP. “When we came to BK Print Pack, they showed us a room and enquired if we had a CTP that could fit in that room. The CTP they presently have was a perfect choice. Kodak CTPs have always displayed robust small footprints,” asserts Ashish. Furthermore, the space saving footprint has other advantages, like fewer electrical installations, fewer air conditioning equipment and peripherals like the drainage etc. The Kodak CTP presented a clear win-win situation for BK.
Apart from going for the latest equipment, BK Print Pack has been quite innovative in its day to day operational approach. They are the pioneers of using the process-free plates for re-prints, which is a rare thing with these plates. “Normally we don’t use process-free plates for re-prints – they are not developed for that purpose. However, BK Print & Pack has astutely created a process of their own for preserving and storing their plates to later use them for re-prints,” shares Ashish. “On knowing this, one of the experts from Kodak paid a visit to our plant to understand the feasibility and efficacy of using the plates for re-prints. It is an art!” declares Sandeep.
When the possibility of process-free plates for reprints was first considered, the idea was originally to have a committed team to follow and adopt the exact process, so that the plates can be used as such. BK Print & Pack was quite committed and went to the extent of appointing a dedicated person to ensure that due process is followed and the plates for re-print produce the same quality time and again. “It’s over 5 years since the Kodak installation and till date they have been using the plates for re-prints and can proudly claim to have acquired the expertise in this realm as well,” says Mr.Natesh.
The CTP was bought in April 2017. They visited Print Pack India that year where they decided on the Kodak CTP in no time and the device was up and running within one month. Kodak Achieve platesetters are quite popular with printers especially packaging providers. The processless CTP wins over conventional by way of cost saving because there is no processor. Also, there is long run capability of processless plates where no baking is required. Finally it is significant saving on power that the process-free plates and CTP bring to a set up. “The Kodak Achieve is a very robust solution. Apart from saving by way of process, power and processor, it is quite robust as we have experienced during our 5 years with the device. It has run for us trouble free,” asserts Sandeep.
Expanding into Corrugation
Speaking about their entering into corrugation packaging segment, Sandeep says, “We had to plan beforehand the minimum requirement of a corrugation plant because it is generally a big investment decision, particularly for an automated plant. It is altogether a different ball game – it’s all about big volumes and thin margins. We had to move through a lot of discussion on the 5-ply corrugation plant before finalizing it. The clientele was there, we had significant ready demand there for corrugation packaging. Therefore, it was an easy decision in its favour,” explains Sandeep. It also proved an effective proposition for the customers as they now had their one stop shop for all their packaging needs.
BK Print & Pack with around Rs.60cr. turnover last year is making strong strides into diverse packaging segments and locations enabled by their technological prowess. They are also planning supply network expansion at some key locations. They have registered around 10 percent growth year on year though the pandemic years had been stable by volume. Sandeep hopes to pick up the usual pace this year and is pretty upbeat about the growth ahead. “The business must grow if not month on month, then year on year!” asserts Sandeep Singla.
BK Print & Pack has bought one brand new Komori recently which adds up to a whole Komori lineup they already had. The recent addition has been a 5-colour Komori coater press which they acquired this year. The one before was acquired as refurbished Komori, which is a 6 colour UV press. Both pressed are 28×40 size, which not only makes it an increased capacity but also bestows the capability to produce the same job on either press or on both simultaneously as per the requirement. The latest Komori is the latest advance model; only two such models are running presently in the country. The other one is installed in Rajasthan.