The diversity of the packaging industry keeps increasing with newer trends evolving every few years. Additionally, the transforming consumer expectations for packaging that is informative, eye-catching, as well as sustainable, have all contributed to the transformation of the sector. With a wide array of options, the packaging industry in India is huge, with various players specializing in diverse product ranges.
A significant vertical within this industry is the HDPE Blow Molding and Injection Mold Containers, which often also feature Inmold labels. The demand for these products is particularly high in the pharmaceuticals and F&B sectors, which demand high-quality packaging that is not prone to damage. However, concerns about packaging quality, lid breakage, and subpar product finish pose a great challenge for consumers.
Kavitha Polypack, an ISO 9001:2015 certified and FSSC22000 certified company based in Cochin, has enjoyed a prominent position in this sector as the leading supplier of diverse containers, equipped with its unique sealing technology across Kerala. Lending a particular focus on the quality of its products, Kavitha Polypack not only ensures meeting the highest industry standards, but also ensures surpassing client expectations every time.
Assortment of Products
Offering a wide selection of container types, Kavitha has successfully dominated the ice cream container market and is now expanding its scope by penetrating more industries. With a legacy of supplying ice-cream containers to top companies in Kerala, the firm is now diversifying into the bakery and hotel containers segment, offering a wide range of food grade, virgin plastic injection molded, and blow molded packaging solutions.
The company has been a major supplier of food and dairy containers across Chennai, Karnataka, Pondicherry, and other surrounding states and plans to capture about 8-10 percent of the market shares by 2025. The firm offers several SKUs with its flagship product being the Plastic with IML label, offset printing in up to 6 colors.
“We have established our brand in a very short time and now we are a proud supplier to many leading ice cream companies in India. With state of the art production facility, imported special purpose machines, and trained staff, we assure quality food grade, virgin plastic injection molded and blow molded packaging solutions for ice creams and dairy products”, shares Dileep. M.P., Managing Director.
Specializing in IM labeled containers, the company boasts an impressive portfolio of products and a state-of-the-art facility equipped with imported special-purpose machines that ensure high-quality products. Moreover, the trained and skilled staff ensures the products manufactured and sold meet the client's expectations perfectly. Aligning its product offerings with market demands, the company offers exquisite In-Mold Label containers that fulfill the criteria for lightweight, aesthetically pleasing, and eco-friendly products.
This process also offers flexibility to the clients in terms of color selection, improved product visibility, as well as choosing recyclable materials which further impress endconsumers. Kavitha’s containers also feature various resin colors and freezer grade materials, sealable and tamperevident, generic products customized with IML labels in 3 or 5 faces as well as wraparound configuration.
“On curved or non-parallel surface plastic containers such as yellow fat tubs, IM labeling delivers higher quality decoration than direct decoration methods such as tampo/pad printing, which are limited to flat surfaces.
The sustainability benefits of IM labels are increasingly appreciated by end users faced with reuse and recyclability mandates.
Where a polypropylene IM label is used on a PP container, the whole package can be recycled in a single process without having to remove the label. And, of course, compared to PS labels no release liner waste is generated, and no adhesives are required”, shares Dileep M. P., Managing Director.
Production Excellence
“Our vision is to be a global destination for the safest and cleanest packing solutions, through innovation and to be a leader in the industry by adopting technological applications to develop the best products resonating with market demand. Moreover, it is our mission to maximize productivity and customer satisfaction by achieving the highest efficiency levels, using minimum resources and saving them and the environment for future generations, creating safe and healthy working conditions for our employees, and above all not deviating from basic values and ethics of business”, shares Dileep.
With this vision and mission at the core of its operations, Kavitha Polypack has an excellent and comprehensive production process set up to ensure the high-quality and error-free manufacturing of containers. “Our process starts with initial understanding with the client to understand the requirements.
Thereafter, a prototype for the container is developed for the client based on the quantity and style required. Once that is approved the process of in-house labeling starts and a sample of the design is sent to the client for approval. Once all the approvals are attained from the client, the product goes in for commercial production”, shares Dileep.
Throughout production, minor glitches or incidents can cause significant structural damage to the containers such as dents, bumps, burn marks, and more, which if unnoticed can cause recall for the entire batch of containers from the clients. To prevent that and offer clients only a pleasant experience, the company employs stringent quality control measures which include steps like thickness testing which helps assess the thickness of the container, to ensure the thickness is uniform and as per the set standards for its use.
Another measure includes label adhesion testing which ensures that the labels are correctly stuck to the container, preventing any chance of peeling or detachment. Moreover, visual inspections to examine every tub for imperfections or defects are carried out to ensure structural integrity and aesthetics.
Kavitha Polypack has an excellent & comprehensive production process set up to ensure high-quality & error-free manufacturing of containers
The firm also stands out for its in-house label designing capabilities aligned with the needs of individual consumers. This feature has earned the company over 350 customers across South India. Moreover, the firm has also automated its sales force division with SFA software.
Journey & Future Progression
Kavitha Polypack’s journey has been marked by phased growth since its inception 10 years ago. Starting with 15,000 pieces a day with today's 6,50,000 pieces per day there has been an enormous increase in the production capacity with fully automated robotics applications imported from Germany which gives a perfect blend in the end products.
Experiencing steady growth since its inception, the company has always focused on increasing machinery, thereby increasing its production capacity, as well as increasing its manpower. With the firm’s growing customer base and the addition of new SKUs, the demand for high-quality Kavitha Polypack products is on the rise.
The IM Labeling and HDPE packaging sector is anticipated to grow manifold in the coming years with the demand for sustainable and visually appealing packaging containers being one of the main drivers of this progress. As the industry gears up for this upcoming growth, Kavitha Polypack is also shaping its strategies to align with future trends. Starting with product diversifications to include high-end food containers, and manufacturing them in large quantities, the firm is seeking to come up with solutions to meet the rising HORECA sector demands.
Moreover, the company is investing heavily in R&D for brand impact analysis across its existing and new customers to assess the performance of its products, which will further help it pivot its strategies for improvement. Making greater innovations in IM labeling for packaging, the company will strive to continue expanding its range of offerings, which will propel it to greater achievements in the coming years.
"Following the recent Gulf Food Exhibitions held in Dubai and in response to significant customer expectations, Zora Pack, Dubai, an initiative of the Al Ras Group and Kavitha Polypack, was established in April 2023 as part of a global expansion plan. We stand as one of the pioneering companies in both India and the U.A.E., specializing in the manufacturing of in-mold labeled (IML) containers. Zora Pack's current production capacity stands at 1 million units per day.
Our expertise in IML container manufacturing stems from our unwavering commitment to investing in the expansion program devised in collaboration with the aforementioned group across the Middle East. Kavitha Polypack, in association with Al Ras Group, is also actively planning for expansion into the Middle East market as its next destination. We take pride in being recognized as a brand affiliated with Al Ras Group", shares Dileep.
