This new plant, which was inaugurated recently, will manufacture mono cartons. Towards this, the company has equipped the 2,700-sqm shopfloor with a new five-colour 28x40-inches Komori GL online coating printing press and a sheeting machine, supplied by PackSys India and manufactured by Hoi Sheng Machinery, Taiwan.

The Lithrone G40 promotes green printing by reducing consumable and energy usage and lowering carbon footprint. The press comes with Komori’s KHS-AI technology and a maximum speed of 16,500 sheets per hour.

On the investment, Sandeep Kumar Jain, managing director, Omega Printopack, said, “We were struggling with our printing press because we only had a four-colour Komori Lithrone and it was overloaded. So we decided to buy another press.”

Jain said Komori was the first choice because the company was aware of the machine’s quality and after-sales services. “We always get services within 24-hours since registration of complaint. That gives us strength because it means a lot if we get such after-sales service support in a city like Haridwar,” Jain added.

The Komori GL40 ensures high quality print with unsurpassed productivity and can easily handle the increasingly frequent short turnaround jobs and ensures exceptional productivity and high profitability to the customer.

The machine can run at the maximum speed of 16500 sheets/hour and it was ran at it full speed in a demonstration during the inauguration of the plant. “The press has strengthened our portfolio because we can now print more in less time with more colour and effects,” Jain added.

Jain started his career as a supervisor and earned Rs 1,800 per month. In 2003, he left the job and started as a print freelancer. Today, he is doing business of more than Rs 30-crore per annum, while converting around 250 tonne of paper and boards per month.

“Our initial annual business was hardly of Rs 3-crore. We expect that in the coming decade, will be doing annual business of more than Rs 100-crore,” he said, adding that nowadays business is very tricky and you need to save money.

This is the reason why Omega has installed a web-to-sheet sheeting machine. “We buy paper in reels and cut those reels in sheets according to our requirement. Our newly installed HSC 1400B can run at the speed of 300-cuts/min or 300-m/min.  It can handle paper and board from 50- to 550-gsm and it is equipped with slitting, double decurler and web aligner.

Akshat Jain, the second generation, joined last year and implemented solutions for more transparency and smooth production. He has put the entire process on Google sheets and is going to give access to his clients to that they can check the process of their jobs online. He is an IT graduate from Galgotia University, Greater Noida, and is implementing things to make the system self-driven.

On the future plan, the junior Jain said, “Our second plant is in a rented premise. We will merge it with one of our existing plant soon. Then we will separate our business of mono cartons and corrugation.”

Currently, 60% of the company’s business is mono cartons, rest is corrugation. In future, Omega plans to go for paper sticker printing machine and an automatic corrugation plant. And for scaling up corrugation production, another Bobst Novacut die-cutter will be installed soon. The company has installed Paktek flute laminator too.

Around 350 people work round-the-clock at Omega. “We have implemented our own production management system (PMS) and created a new post ‘customer relation manager’ to serve our customers better,” Jain said.

The ISO 9001:2015 certified print production company also follows lean management and 5S, and serve clients from pharma, electrical, stationary and others.

The Omega growth story

2003: Started as a freelancer

2004: First lamination machine

2006: Partnership firm converted to private limited

2009: Got the plot in SIDCUL

2010: Established the first plant in a 3,000-sqm (33% constructed) area dedicated to mono cartons

2015: Komori Lithrone to provide quality print production, along with Bobst die-cutting and folder-gluer

2018: Second plant spread over 1,000-sqm area for corrugation E, narrow and broad flute (a DGM folder-gluer was installed recently)

2020: Third plant spread over 2,700-sqm area dedicated to mono cartons