Surya Fresh Foods Increases Productivity With Upgraded BOBST NOVACUT 106 E

Headquartered in Greater Noida, Uttar Pradesh, Surya Fresh Foods is a subsidiary of Surya Food & Agro, producer of the famous Priyagold Biscuits, and a prominent player in the food industry.

Known for its diverse product range, which includes high-quality biscuits, fruit juices, and chocolates, the company was established in 1992 and today operates multiple plants across India.

With a strong focus on quality and innovation, Surya’s commitment to brand building, distribution capabilities, and product quality has solidified its position in the food industry. In 2014, the decision was made to accelerate its print and packaging production in-house by installing, amongst others, a BOBST NOVACUT 106 E Autoplaten die-cutter and a BOBST folder-gluer. Now, under the visionary leadership of Director Shrey Agarwal, a significant leap in efficiency has been implemented, with the NOVACUT 106 E undergoing a substantial upgrade program.

The retrofit to the flatbed die-cutter has added a non-stop feeder and a machine elevation system for optimizing output of cartons for biscuits. “We’ve revolutionized our BOBST machine with these upgrades, successfully enhancing its capabilities and addressing our previous operational limitations,” declared Mr Agarwal. “These enhancements have significantly increased production speed, allowing for a continuous workflow and a substantial boost in output.”

Quantifiable impact on performance
The results speak for themselves. Previously, the BOBST machine needed to stop for reloading after every 650 sheets. Now, with the capacity increased to 950 sheets, the frequency of pile changes has been significantly reduced. In addition, the production speed has surged by 40%, while maintaining the same level of high accuracy and excellent quality. Importantly, this improvement comes without additional maintenance costs. The operators and maintenance crew were quick to adapt to the upgraded system, getting to grips with it in a week.

“The BOBST team is pleased to have collaborated with Surya Fresh Foods to address its productivity challenges and unlock the full potential of its NOVACUT 106 die-cutter through targeted upgrades. This investment is a testament to the great partnership between BOBST and Surya, ensuring a long-term asset that delivers both versatility and productivity,” commented Gurvinder Singh, BOBST Service Manager – Indian Subcontinent Business Unit Services & Performance.

The costs of the enhancements are also minimal compared to the long-term benefits, as Surya Fresh Foods has effectively eliminated the die-cutting bottleneck in the production workflow. The calculated return on investment (ROI), based on the 40% efficiency increase, is expected to be around just eight to nine months.

Aligned with future strategy
The recent upgrades to the BOBST NOVACUT 106 E machine align perfectly with the company’s growth strategy. Having initially considered buying an additional machine to meet the increased demand, Surya Fresh Foods is now efficiently fulfilling this demand with the existing BOBST NOVACUT 106 E machine.

In essence, this investment exemplifies strategic foresight and technical ingenuity, setting a benchmark for transforming existing machinery to meet evolving production demands.

Looking ahead, Mr Agarwal anticipates further enhancements of the die-cutter to continue on this path of innovation and expansion. “We’re planning to integrate an auto-blanking system to further streamline our operations,” he revealed. His leadership, supported by BOBST’s technology, ensures that the company will remain at the forefront of innovation, ready to tackle any future challenges.