Future trends in packaging

Ajay Mehta of SMI Coated Products. Photograph PSA

KRBL to add 500 tonnes per day capacity in SonepatA premium commodity – India Gate Basmati RiceOne of India'southward best known packaged food commodities, basmati rice uses flexible packaging for both domestic markets and exports. Packaging South Asia visited India's largest rice miller and exporter, Khushi Ram Bihari Lal (KRBL), a few miles off NH24 on the route from Ghaziabad to Bulandshahr. With its 120-year-old basmati rice make, India Gate, the `3,000 crore company is the market leader amongst companies such as Lal Kila of the Amritsar- based Amar Singh Chawal Wale, Dawat of LT Overseas, Kohinoor of Satnam Overseas and Best brands of basmati rice and prepare-to-consume delicacies of Best Foods.India Gate Basmati Rice being stacked on pallets at the KRBL plant in Ghaziabad. Photo PSAThe sorted, packaged and branded basmati rice marketplace was initially driven by exports with very fiddling domestic consumption. "We started with a small unit in Alipur in Delhi that used to produce long grain caput rice (unbroken basmati) exclusively for the consign market," says Ashok Chand, CEO of KRBL.

KRBL's second rice mill and found was established almost Ghaziabad in 1998 on an 18 acre site which has since been expanded to 110 acres. "All the caput rice was exported in those days while all the broken rice was sold in domestic markets. The head rice yield for raw rice was effectually xl% to 42% while the head rice yield in the example of par boiled rice was around 50%," says Chand, a professional engineer who joined the company afterward a long stint in EIL, Nestle and Pfizer.

"When nosotros started branding the packaged product for the domestic market, the Group chairman, Anil Kumar Mittal, lay downwardly the bones principles – maintaining product consistency and keeping to the committed word at all times. Bharat Gate Basmati Rice owes its leadership to the fact that rice picked up from the store shelves in the Americas is exactly the aforementioned as that picked upwards from shop shelves across India. We take various categories like the Republic of india Gate Basmati Rice Archetype, Republic of india Gate Sella (par boiled rice that drives nutrients similar thiamine from bran into the grain), Republic of india Gate Durbar, Tibar, Mogra and Mini Mogra that are broken rice and segregated under different product classes, just we maintain consistency in each category," says Chand.

The book of basmati rice sold in domestic markets has increased manifold due to the processing, sorting and branding and is now equal to basmati exports. At times the toll realization in domestic markets is even meliorate than overseas, though in nearly cases it is at par with the internationally sold product.

The Ghaziabad mill processes 1,000 MT of paddy a day while the Dhuri rice factory at Punjab processes 2,500 MT of paddy a 24-hour interval. After accounting for the husk which works out to about 20% to 25% of the weight and rice bran which is another 7% to 8% and other wastage, the yield is usually 62% past weight. This is the raw rice that is further classified and sorted in various segments with the loftier quality head yield of over twoscore% used for the premium category. The rice husk is used as fuel for the co-generation plant while the bran oil is extracted and sold to oil mills for further refining, packaging and marketing.

Hassia packing lines
KRBL uses packing, filling and sealing machines from Hassia Packaging for bagging 1 kilogram to x kilogram bags. Printed flexible packaging material is bought from Huhtahmaki PPL, Paharpur and other packaging suppliers. "We use around seventy to 80 tonnes of flexible packaging material each month in all our plants combined," says Chand as more and more than rice is now being sold in flexible packaging pouches.

Apart from the large KRBL mills in Ghaziabad and Dhur, KRBL is setting up a fully automated institute at Sonepat just N of Delhi for processing and packaging rice from the intermediate stage after de-husking. To be operated by 20 employees, the 500 tonnes per day (TPD) constitute will accept automated conveyors, handling systems and packing lines.

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