Toph Packaging enhances capacity with Nova A5

Priyank Virmani, co-founder of Toph Packaging, said, “We are not originally from this industry, so we approached this investment with fresh perspectives. We have been using an Alliance 9-colour single servo press for the past nine months, along with an offline slitter from Alliance and an inspection camera from E+L. Our experience with Alliance was very collaborative; we provided feedback during our R&D phase, and they incorporated our inputs into the final design."

The Nova A5 press features PLC programming and servo-based operations, with an interface customized for ease of use. "We are habitual to Bobst machine, and Alliance made sure that the user experience remained similar. Both machines look alike and function with high registration accuracy, making it a smooth transition for our operators. The Nova A5 is equipped with nine lamps—two LED and seven conventional—along with standardised aniloxes, ensuring seamless integration with our existing setup," Virmani added.

With a web width of 450-mm and a mechanical speed of 150-m/min, the Nova A5 is designed to handle high-volume production efficiently. "Our existing machine was running at full capacity, operating 24/7. We started exploring options when we had already reached 60% of our required backup capacity. While we initially considered Bobst again, factors like lead time, cost, and the rising Euro made us reconsider. European presses have a tough ROI period of about three years, so we needed a workhorse that could deliver without financial strain. The Nova A5, installed in July 2024, was the perfect fit."

Toph Packaging has witnessed a 70% sales increase after installing the new machine. “We had orders but lacked the capacity to fulfill them. Now, we are expecting 100% growth in the next financial year. The Indian machine manufacturers are catching up with global standards, and Alliance was flexible enough to customise features like registered gear systems, locking mechanisms, and pneumatics to meet our requirements. After rigorous trials, we finalised the Nova A5, and it has even handled complex print jobs efficiently."

The company is also exploring digital printing as part of its growth strategy. "Haridwar has been a great market for us. We have strong clients, and our approach is more service-driven. Quick decision-making, prompt outreach, and regular training sessions have been key factors in our success. Most production issues arise from materials, processes, or human factors rather than the machine itself. With my background in business analysis, we focus on identifying root causes and implementing solutions."

With a team of 45 members, Toph Packaging prioritises team-building and employee well-being. "We conduct trust-building exercises, meditation sessions inspired by Mata Nirmala Devi Ji, and employee welfare programs. Our philosophy is that the team should grow along with the company."

The company’s infrastructure is also evolving with a focus on sustainability and process optimisation. "We have automated plate cleaning, an in-house ink kitchen powered by Flint, and standardised waste management. Our plant is well-organized, ensuring clarity of processes. We also utilise clean energy with a 60 kW solar power setup. The facility has expanded significantly and its area has now doubled."

Looking ahead, Toph Packaging plans to enhance its capacity utilisation further, especially for the pharmaceutical segment and aims for backward and forward integration. "We are scaling up across offset, digital, and flexo printing to meet the evolving demands of our customers," Virmani concluded.