Internship Report Profile of the Industry Companies place great significance on the packaging of a product, since customers make

quick judgments about products based on packaging. The packaging of a product communicates brand, image and usage. Packaging has accompanied mankind throughout history from the early days when primitive humans lived as nomadic hunters/gatherers. Early packaging was done by typically wraps of leaves, animal skins, and shells of nuts or hollow wood pieces. Packaging has developed tremendously since those days, reflecting human society development via domestication of plants and animals to farming followed by industrialization and later information and knowledge society. Throughout these stages different style packaging has always been around, to support cotemporary lifestyles.

The need for packaging isnt something new; it has always been there and still is. What has changed is the way of how things are packed and to be honest, it has evolved. Also new growth segments, such as active and smart packaging, often have long roots in history. A wooden cask is an early example of active packaging for wine with beneficial effects on quality in the maturity in the maturity and aging process for wine. Right now, all across the world, many companies are providing packaging material and one of them happens to be Packages Ltd.

Packages Ltd has helped us in more then one way. It provided us with organizational knowledge, polished our marketing skills and also helped us in drawing a thick line between theoretical and practical world.

Profile of the Company Packages Ltd was established in 1956 as a joint venture between the Ali Group of Pakistan and Akerlund and Rausing of Sweden, Packages Limited provides premium packaging solutions for exceptional value to individuals and businesses. Packages Limited has the philosophy to fulfill the needs of customers and consumers with the focus to be the market leader. Our clientele includes illustrious names such as Unilever and Pakistan Tobacco Company, who have been our customers for over 50 years. Strong leadership, innovation and efficiency improvements are the keys to achieve this goal contributing to sustainable development. In 2012, Packages Limited had annual sales of around Rs. 21 billion. Listed on all three stock exchanges in Pakistan, Packages Limited has maintained a long-time credit rating of AA. Their joint ventures and business alliances with some of the world's biggest names reflect their forward-looking strategy of continuously improving customer value through improvements in productivity. Packages has always been at the forefront of new developments in packaging research and has pioneered several innovations, including the use of wheat straw as a raw material for paper and board manufacture. Our on-site paper and board mill, established in 1968, has constantly increased its production capacity. A new plant with even greater capabilities is planned for the near future. Paper and Board Packages Limited has been producing high quality Paper and Board since 1968 using environmental friendly manufacturing processes. In 2005, Packages Limited invested in a Green Field Project in Kasur by the name of Bulleh Shah Paper Mills and has installed latest state of the art Paper and Board manufacturing facilities. In 2012, the Scanidavian paper and packaging manufacturer Stora Enso has concluded a joint venture called Bulleh Shah Packaging Limited with Packages. This is one example of Stora Ensos sustainable and value creating investment in growing markets explained Mats Nordlander, Executive Vice President, Renewable Packaging at Stora Enso.

Company Business Processes There are three business units of Packages, carton line, flexible and corrugated boxes. Out of the three our focus lies in carton-line Off-set for now. I would really like to thank Mr. Wasik Ali, the in charge of planning, and Mr. Ali Rabbani, the Business Unit Manager for Carton line Offset, who helped me in gathering information related to Offset Carton line. There are six departments of carton line offset printing, cutting and creasing, planning, folding and gluing, development and cup making. Carton-line flexible is also about printing, converting and boards. There are three different types of boards used while packing a product. These boards are duplex, which is preferred by Nestle, and rose petal, bleached, which is preferred by Unilever and card board, which is preferred by ice cream makers. Out of the three, duplex happens to be the cheapest then its bleached and the most expensive is cup board. It solely depends on the customer which board he likes to choose for his product. Packages gets these boards from various suppliers like century paper mill, import it and now its time they have started making their own boards in Bulley Shah paper mill.

Web (Unprinted Board Reel)

Printing

Cutting & Creasing

Packing of Finished Product

Trimming

Embossing

Quality Checking

Dispatching

The workflow of business unit folding carton: This all starts up when the sales people bring in business. An internal sales order (ISO) is issued, which carries the name of the customer, the shipment date, inks and boards that should be used etc, by the sales department right after a purchase order is released from the customers that state the needs and requirement of the customers. The production order is created according to the information and is then send to the carton-line flexible unit for production. Be it Off-set or Roto. The ISO is sent to Mr. Ali Rabbani who happens to be the Business Unit Manager of Carton-Offset. He gets started by informing the production manager, planner and development department about it. From there Production manager creates a production order, as said earlier, and send it to Wasik Ali, the head of Off-set Printing, Talal Najam, the head of cutting and creasing, Bilal, the head of folding and gluing and Atif Raza, the electric head. If the printing needs to be done on Off-set, it is send to Wasik Ali, the head of Off-set printing, along with the three departments mentioned above. If the printing needs to be

done on Roto, the production order is sent to Omer Mehmood who happens to be the head of Roto printing, along with the three departments mentioned above. List of the products for Off-set:

Hoor Beauty Soap (Soap Industry) Nido (Dairy industry) Fair and lovely (Cosmetics Industry) Capstan (Tabacco Industry) Rose petal (Tissue Industry) Nestle cerelac (Dairy Industry) Mitcheles chocolate box (Confectionary) Rafhan jelly crystals (food items) Shan karahi/fry ghosht masala (Food items) Rio biscuits (confectionery) Everyday (food item) Golden Peral (soap and cosmetics industry) Johar Joshanda (Medicine industry) Nestle Lactogen (Food item) Disprin (Medicine Industry) Tapal Danedar (Tea industry) Omore Chocolate (ice cream industry) Tarang (food item) Sharbat-e-faulad (medicine industry)

Company Departmental Functions

Main operations of Packages Ltd. Lahore include: Manufacturing paper and board. Preparing packaging for hundreds of industrial and consumer goods. Production of its own consumer goods e.g. Rose Petal and Tulip tissues, napkins, paper cups etc.

Some other main departments of Packages Ltd. are: Finance division Commercial and Purchase department Industrial Marketing & Sales department. Research, Development & Control department. Art Department MIS-Department Reproduction Department Planning departments Personel & Industrial Relations department.

Machine printing at Packages Limited is divided into two types, namely, Offset and Rotoline Printing. Rotoline printing mainly includes the printing of cigarette packets, whereas Offset printing includes printing of medicine, tea, biscuits and cosmetics cartons. 1. Rotogravure This is an in-line process that uses a 7 color machine. The web is in the form of an unprinted board reel. After printing, the sample is cut and creased and then embossed and trimmed. The finished product is packed and released after the quality has been checked to be up to standard. Roto requires two machines, Lumanic and Riviera, to carry forward the task of printing,. However it deals with high volume and cost. The products of Pakistan tobacco is being printed on roto. Types of Rotogravure Machines: Riviera DR 67 Printing State of the art printing technology Cutting Segmented Rotary Cutting tool Creasing Rotary Monoblock creasing Embossing Rotary Segmented Embossing Delivery Ready Speed flow

Monomatic Zero speed Splicing

Speed: 275m/min

Major Jobs: Cigarette HLs

Lemanic CH 82 Printing State of the art printing technology Cutting Flat Bed Die Cutting Creasing Flat bed Die Creasing Embossing Rotary embossing rollers Delivery Ready speed flow

Monomatic Butt joint splicing

Speed: up to 210m/min Major Jobs: Cigarettes HLs

Merits of Rotogravure: All the processes are done in-line Special metallic colors are very rich Very cost effective for longer runs Quality production Consistent shades in printing

Demerits of Rotogravure: High cost as compared to off-set We have to move from one variant to another

2. Offset Printing This is a sheet-fed printing process. The planned size is received at the business unit folding carton (BUFC) and is converted into multiple. The BUFC checks the feasibility i.e. on which machine the sheets can be run depending on how critical the job is and furthermore, on which press they should run. The layout is formed according to this information and the sheet sizes too are cut accordingly. Off-set deals with low volume and is usually found to be cost effective. Step wise production takes place in Off-set. The first and foremost step is printing, second is cutting and creasing, third is folding and gluing and last is dispatching. These operations are carried forward by different machines. The operation of printing is done on four machines, number 9, number 8 is used for five color jobs and R1 and R2 machines are used for six color jobs. Water base and UV takes place on number 22. After that the operation of cutting and creasing takes place on

machines number 2, 15, 9, Speria and Evolian. The next operation is to fold and glue plus window batching the cartons (if needed) and to carry forward that operation four machines are used. The products of Unilever, Nestle, Tapal, English biscuits, Rose petal, Qarshi, Engro are printed on Off-set. He added that 100ml and 60ml paper cups are printed on machines number 1, 2, 4 and 5.
R&D Department Packages consist of a Research and Development department which looks after the trouble shootings that takes place in the business units; be it carton line, flexible or carruwall. It also takes into account post and pre testing of the board. More over R&D department helps in researching for new products and recipes. To find out how the entire R&D operation is conducted, I visited the R&D department today where Mr. Zohaib sent me to Mr. Babar Rafique, in physical lab. R&D department consist of four labs: 1. Chemical Lab 2. Pulp Lab 3. Flexible Lab 4. Physical Lab My main focus was to figure out the physical properties of Dawn Frozen Food cartons. This took me to the physical lab where Mr. Babar Rafique, the supervisor of the physical lab, provided me with the information that further helped me in carrying forward my task. The purpose for this was to determine the number of flaps and the type of board used by Dawn and compare it to Sufi Frozen foods. The sales team wanted Dawn as a potential customer and they needed all the information before approaching the client.

Method
The first stage is to measure the gramage. This was done by cutting the carton from centre, with the help of a cutter and metal plate of 10x10, and placing it on the weighing machine. The second stage is to find out the thickness of the carton. The greater the thickness of the carton, the greater will be the gramage. This was done by measuring the thickness of the carton through four different sides.

The next stage is to measure how much moisture the carton carries. To carry out this measurement, a specimen of the carton is placed in the oven twice. You know your answer when the digits stop to roll and give a constant value. This is repeated again and percentage is calculated by subtracting the values. This normally takes two to three hours.