Bulk Pack 2010 International Conference
was held at the Novotel Convention Centre in Hyderabad,
India on the 8th and 9th of April, 2010. It was staged concurrently
with the India Packaging Show 2010 and
Bulk Pack 2010 which took place at the
HITEX Exhibition Centre at Hyderabad.
‘Towards a Modern Bulk Packaging Infrastructure’
as its theme, the Bulk Pack International Conference was
sub-divided into 4 half-day sessions, each of which highlighted
a particular aspect of Bulk Packaging. More than 100 delegated
attended each of the sessions on both the days and were
delighted to have one to one interaction with both national
and international speakers.
Conference was organised by Print-Packaging.Com Pvt. Ltd.
in association with the Federation of Andhra Pradesh Chambers
of Commerce and Industry (FAPCCI) and was sponsored by
ITW India. With Automation Industry Association as its
knowledge partner, the seminar was also supported by the
Indian Flexible Intermediate Bulk Container Association
(IFIBCA), the All India Flat Tape Manufacturers Association
(AIFTMA), the Bulk Drug Manufacturers Association (India),
the All India Food Processors Association (AIFPA), the
Hologram Manufacturers Association of India (HOMAI) and
the Indian Biscuits Manufacturers’ Association (IBMA).
1: Bulk Barrier and Aseptic Packaging
Session 1 commenced with a white paper on the Indian Bulk
Packaging Industry by industry consultant S. Chidambar.
The paper was aimed at presenting the findings of a detailed
market study carried out by him on behalf of Print-Packaging.com
and to quantify the major segments of the Indian Bulk
Packaging industry. The study identified most of the important
bulk packaging systems being used and manufactured in
India. Not many people are aware that the bulk packaging
business – mainly industrial packaging for use by
large manufacturers and distributors - accounts for over
40 percent of the total packaging spend in the developed
countries. Even in India, where the focus of the study
was only on applications that require a reasonable ‘technology’
or ‘packaging’ input, the total annual revenues
identified were in excess of Rs 26,000 crores.
packaging systems are designed primarily for handling
industrial inputs like basic materials and intermediates
in bulk & components and for bulk transporting and
distribution of even small unit retail packaged goods.
There is a substantial overlap between bulk packaging
and some other technology areas like warehousing, materials
handling, transportation and logistics, storage and retrieval
systems both in-plant and across the entire supply chain.
To a large extent, the state of this industry is dependent
on the quality and efficiency of infrastructure that exists
at the premises of both manufacturers and end-users as
well in the public domain like transportation systems,
roads and highways, railheads, ports and distribution
and trans-shipment centres. If taken into account a relevant
portion of these industries, the total bulk packaging
business in India could well be worth between Rs 30,000
and Rs 35,000 crores per annum. The actual growth and
acceptance of bulk packaging applications is constrained
by the present availability and quality of infrastructure,
knowledge levels on how to handle bulk packages and the
significant upfront investments required although the
derived benefits in terms of convenience, time saved,
lower manpower deployment and savings in total system
costs are substantial. An interesting finding was that
the Bulk Packaging solutions providers in India are very
competent and are, in fact, global leaders in several
segments despite the low domestic demand for their systems.
Overall, the growth potential and outlook for Bulk Packaging
in India are very promising.
paper was followed by a presentation on ‘Bulk Barrier
Packaging for High Value Tea Storage and Exports’
by P. Dasgupta of Hindustan Unilever. He presented the
findings on experiments carried out by them to identify
the critical barrier parameters for maintaining preserving
high quality tea. They identified these as prevention
of moisture ingress and prevention of oxidative deterioration
of some key volatile ingredients. They then tried out
high moisture and gas barrier bulk flexible bag systems
placed inside corrugated cartons evaluating both nitrogen
flushing and vacuum packaging for excluding atmospheric
oxygen. He showed video clips of both variants and concluded
that both were found to be suitable although, ideally,
the flushing process needs to incorporate both vacuumisation
and nitrogen flushing.
was followed by three presentations on flexible bag-in-box
and bag-in-drum systems for both aseptic and non-aseptic
applications by Rajesh Ainchwar of DuPont, M.G.Dixit of
Scholle Packaging and Zizzi Guglielmo of Goglio, whose
companies are the world leaders in these technologies.
Many interesting options were discussed including special
valves for venting of gases developed by processed products
during storage after packaging, sensitive food products
like fruit juices, dairy products and beverages, the critical
requirements of maintaining asepsis and the handling of
materials in bulk by reinforcing flexible bag systems
with external protection using steel or plastic drums/corrugated
Buddha of Dr. Reddy’s Laboratories then presented
a paper on ‘Challenges of Bulk Barrier Packaging
for Pharmaceuticals’. The bulk products handled
by this industry are mainly bulk drugs and some ingredients
that are mostly in powder form, which are shipped in fibre
drums and FIBC’s. The other bulk packaging system
used is for transport packaging of unit packs is CFC’s,
which are usually palletised and stretch wrapped.
session concluded with a presentation by Ashish Powari
of Sealed Air on ‘Flexible IBC for Aseptic and Non
Aseptic Products’ in which he discussed their system
which uses specially designed flexible laminate bags that
are put into either metal or plastic drums or CFC’s.
Aseptic products are catered to using special accessories
and filling systems for creating and maintaining asepsis.
2: Flexible Intermediate Bulk Packaging & Woven Sacks
Session 2 was kicked off by Anil Kumar of Jumbo Bags,
who is also the President of the IFIBCA. He presented
a paper on ‘Status of FIBC Industry in India’.
He talked about the very impressive track record and capabilities
of this industry in India; its annual output is about
150,000 MT despite the domestic demand being less than
10 million bags per year. It is one of the three largest
producers of FIBC’s in the world.
was followed by a presentation by Makrand Appalwar of
Emmbi Polyarn on ‘Advantages of FIBC in Modern Bulk
Packaging & Material Handling’ in which he detailed
the different varieties of FIBC’s available, their
advantages and their manufacture. The major advantage
of the FIBC is that1 gm of polymer can be used to handle
1 kg of product (1,000 times its weight).
Prakash Moharana of Haldia Petrochemicals then talked
about ‘Opportunities for FIBC for Various Domestic
End Use Sectors in India’. He put the Indian industry’s
output at 134, 000 MT for 2009, of which the domestic
usage is about 28,000 MT. The major end-user industries
are PET/PTA resins, carbon black, alumina and clay.
next presentation, made by Rakesh Shah and Anuj Sahni
of Windmoller & Holscher, on ‘Block Bottom Welded
Woven Sacks’ discussed their new AD proTex woven
sack systems that have a welded block bottom construction
that make them hermetically sealed and easy to stack.
These bags are about 50-70 percent more expensive than
conventional sewn woven sacks.
next presentation was by Dr. Herbert Kielbassa of LABORDATA
International Materials Testing Institute on ‘International
Test Procedures for Safe Handling of FIBC for Dangerous
& Non Dangerous Goods, Single & Multi Trip’.
He outlined how test procedures are set up for FIBC’s
and discussed a couple of case studies.
Sillip of Starlinger then presented a paper titled ‘New
Generation Woven Sack Design, Manufacturing and High Speed
Filling Systems’. He put the global output of woven
sack systems at between 400 and 500 KTPA. Their latest
system provides tape that has a strength of 6 gms/denier
and has a 23 percent higher elongation than conventional
final presentation in this session was ‘End User
Experiences & Expectations from FIBC Industry’
by Vivek Mehta of Indian Oil Corporation, who are the
largest users of FIBC’s in India. He talked about
the significant benefits that they have reaped and provided
to end-users by using FIBC’s for bulk packaging
of PTA. They are also shortly commissioning a new project
for manufacture of polymers with a special focus on the
requirements of FIBC manufacturers.
3: Bulk Rigid Packaging & Accessories
The first presentation of this session was made by B.K.
Karna of the Indian Institute of Packaging, Hyderabad
on ‘Latest Trends in Bulk Rigid Packaging and Test
& Validation Protocols’. He described the various
major rigid bulk packaging systems and the important test
procedures for evaluating them.
Low of Chevron Phillips Chemicals then spoke on ‘Commodity
Polymers for Bulk Rigid Packaging’. He described
the various special grades of polyethylene resins used
for rigid bulk packaging applications.
was followed by a presentation on ‘Evolution of
Metal Drums & Barrels In India’ by Anand Dayal
of Balmer Lawrie. He traced the development and growth
of metal drum and closures in India. He put the present
usage of metal drums in India at 7.5 million per annum.
Patwe of Time Technoplast then made a presentation on
‘IBC – A Proven Bulk Packaging Solution’.
He described the major variants of Intermediate Bulk Containers
(IBC’s) available. The standard IBC has a 1 MT capacity
and can be stacked 4 high during shipment of filled containers.
next presentation was on ‘Ensuring Structural Integrity
and Performance in Bulk Rigid Packaging Using FEA Tools’
by Ravi Dhulipalla of Tata Elxsi. He described how finite
element analysis can be used for structural design in
rigid bulk packaging systems.
Sunkara of Pacopack presented the next paper on ‘New
Freight Saving Square Eco Friendly Fibre Board Drums for
Bulk Drugs & Agro Chemicals’. This described
a new system of fibre drums that have a rectangular shape
to facilitate better cube utilisation and thereby save
on storage and transportation. The drums are made by convolute
winding of 300 gsm kraft paper.
final presentation in this session was ‘Bulk CFC
Based System for Exports’ by S. Ramakrishna of ITC’s
Agri Business Division ILTD. This paper presented some
impressive warehousing and bulk packaging systems used
by them for handling leaf tobacco for exports.
4: Bulk Material Handling & Automation
In this session, a paper on ‘Latest Trends in Automation
for Bulk Packaging’ was presented by Anup Wadhwa
of the Automation Industries Association which highlighted
some new system approaches to automation of bulk packaging,.
There were further presentations on various aspects of
automation in bulk material handling and packaging with
several video clips demonstrating installations where
these had been implemented.
Sivaram offered various solutions in a paper titled ‘Coordinated
Drive Controls for Long Conveyors’, N.L.N. Raju
discussed ‘New Generation End-of-line Solutions
for Bulk Packaging Systems’ and Markus Haasner of
Maschinenfabrik Mollers talked about ‘Advanced Palletising
Systems’ including the need to custom design end-to-end
solutions for palletizing and pallet handling.
Deshpande of Cotmac Electronics presented a paper on ‘Intelligent
Material Handling of Bulk Packaged Goods’, which
discussed special control systems for bulk packaging.
This was followed by a paper on ‘Smart Controls
Using 3-D Sensing’ by Sagar Thakare of IFM Electronic
where he discussed a new range of optical sensors that
could be used to monitor and control levels and volumes
in bulk packages.
session concluded with a presentation on ‘Robotic
Cartoning and Palletising Systems’ by Anil Chaudhry
of ABB in which he discussed new robots designed for bulk
packaging and showed clips of installations in India for
handling liquid beverages and paints. The QA sessions
at the end of each session gave the attendees an opportunity
to put across their doubts and get solutions to their
problems from the experienced national and international
All the presentations made at the conference are available
for viewing and download at the India Packaging Show and
Bulk Pack 2010 website.