A SUMMER TRAINING PROJECT REPORT ON RATIO ANALYSIS IN FLEXITUFF INTERNATIONAL LTD
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HISTORY OF THE ORGANISATION
The flexible intermediate bulk container popularly nomenclature as FIBCs is said to have been first manufactured in the late 1950s / early 1960s in the United States, Europe and Japan. The FIBCs manufactured with polyolefin fabrics were experimented in Uk, Canada and the US around late 1960s and early 1970s.The growth of the flexible intermediate bulk bags that are universally used today is however spurned with the development of the high strength lightweight fabric (polypropylene). The FIBCs are giant size bags in drum or box shapes, with capacities ranging from 250-2000 kg depending on the bulk density of the product. Whereas the basic material is polypropylene (PP), high-density Polyethylene (HDPE) or polyamide (Nylon) are also used. The FIBCs can be custom built to meet specific requirement and also UV stabilized.
The concept of bulk packaging revolves around environmental aspects apart from reducing the cost of packaging and faster handling. They also facilitate to minimize losses in spillage and pilferage and create better working atmosphere.
India witnessed the introduction of FIBCs during early 1990s and has since grown to be frontline manufacturers in the world. Although the domestic market growth is still at a slow pace, the converting industry has found export acceptance and nearly ninety percent of production is exported providing the exchequer an excellent FE earning. Both the domestic demand and exports are envisaged to record excellent growth potential.
Flexituff International Ltd, a company promoted by the renowned Kalani group from Indore. Flexituff has the largest capacity in India (2nd largest in the World) to produce PP woven based products. It has the most modern Plant & Equipments under one roof to convert PP granules to tapes, fabric, printing, extrusion lamination & bag making.
Flexituff is the first company to start BOPP printed & laminated pp woven bags in India about seven years back. It is the leader in Jumbo bags, Big bags and container liners. Due to continuous support and strength derived from its own R& D and the international quality set & maintained by its team of scientists, engineers & professionals, today, Flexituff is exporting to more than 40 countries in the world and has been receiving Best export awards year after year. Flexituff is the first and only Asian company now successfully audited and certified by AIB (American Institute of Food Bakers, USA) and BRC (British Retailers Consortium UK) to make direct food contact bags for supplies to American and European companies. It is also certified for ISO 9001: 2008, ISO 14001:2004, ISO 22000:2005 and HACCP. In addition to three Units at Pithampur near Indore, they are coming up with another most modern Unit at Kashipur at Uttarakhand.
Be it polywoven products (like FIBCs, geotextiles, BOPP bags) or thermo-formed FLEXITUFF INTERNATIONAL LIMITED, world’s largest poly-woven packaging company, occupies the enviable status of being the sparkling jewel in the diverse Kalani Industrial Enterprise - one of the leading and respected business Groups of Central India.
With 4 multi-locational manufacturing plants, combined annual capacities of over 40,000 MT and dedicated distribution footprints in more than 40 countries, Flexituff, with its 6000 strong work-force, has emerged as world’s most preferred one-stop-shop for bulk packaging products and solutions.
Set up to fulfill the demanding bulk packaging and transporting requirements of a host of industries across the globe, Flexituff has an enviable number of attributes working for its most discerning buyers. Economies of scale, the edge of attitude, 100% integration under one roof, global foot print, nearly 2 decades of being in the industry, global manufacturing standards and cost advantage of Asia.
Its state of the art manufacturing facilities at SEZ Indore (M.P.), Kandla (Gujarat) and Kashipur (Uttranchal) measure up to the exacting global norms of GMP, AIB and BRC-IoP. Flexituff’s ISO-9001-2000 certified facility with its integrated manufacturing base permits scaling the throughput to match demanding deadlines.
INTEGRATED PLANT - ALL FACILITIES UNDER ONE ROOF
Flexituff International Limited is one of the very few fully integrated plants is the world. Its 100% integration permits us to deliver our products in multiple options while retaining 100% control over the manufacturing process. Needless to say, Flexituff is fully independent from the vagaries of outsourced material or workmanship.
Last minute change in specifications, add on orders can be quickly and comfortably accom-modated at Flexituff. We are able to maintain full traceability of material and workmanship in our Quality Assurance systems.
Microprocessor controlled extrusion ensure excellent input for the subsequent operations. Extrusion plants at Flexituff - the very life blood of the manufacturing process, are state-of-the-art Starlinger. This ultimate extrusion technology comes alive in the experienced hands of our workforce to process over 60,000 kgs. of virgin polymer everyday. Producing impeccable high tensile strength tapes with optimum elongation - a pre requisite for perfect fabric. Precision winding being the key to weave fine fabrics, all tapes are wound by new generation inverter controlled winders to produce even bobbins. Quality checks begin from the very initial stages of Tape-making. Every lot produced is checked for its Denier, Strength, Elongation and Color.
ASSEMBLING THE FINAL PRODUCT
An intelligent, skilled and trained workforce assembles the components into efficient bulk containers. 21,000 FIBCs a day in addition to Builder bags and single loop bags make Flexituff the largest production facility in the world. Be it Form-stable Q-bag, U.N. Certified Hazmat bag or Type-C/D bag, Flexituff offers the most cost-effective solutions for carrying bulk commodities up to 2500 kgs. Every Flexituff FIBC design is certified by NEL, UK.
The assembly section is planned for neat and clean environment, smooth workflow and strict adherence to Clean Room Specifications. The specially trained work force, qualified for basic intelligence parameters and quality orientation works as a team to deliver consistent product quality. Full scale production for any bag starts only after the first prototype bag has been certified by the QC in all respects, including Load Test. Each and every bag is inspected for all critical and aesthetic parameters.
Environment, Health and Safety:
Since its inception, the Flexituff core values of commitment to safety, health and the environment, high ethical standards and respect for people have been the cornerstone of who we are and what we stand for. Well communicated EHS policies ensure that production targets never override the safety of a person and that as a responsible corporate, we remain an environmentally responsible neighbor in the communities where we operate, acting promptly and surely to correct incidents or conditions that endanger health, safety or the environment.
PLASTIC INDUSTRY AT A GLANCE
Globalization has become the most important message for the development of the industrial sector in India which means the industries have to become both competitive and cost effective. During 2001 Flexituff acquired two large units: Special Economic zone Pithampur and A&R Devision, Mahuakhera Gang. Flexituff world’s Largest Integrated Clean Room FIBC Manufacturing facilities.turiye is the world’s second Largest Exporter of FIBC.
Today, modern Turkiye ranks 17th among the largest economies in the world and 7th in Europe with its GDP reaching almost US $ 500 billion in 2007. The Turkish economy is growing during the last 22th quarters, averagely 7 percent in the last five years. As a result of the eminent change of Turkiye’s economic and trade policies in the early 80’s, its foreign trade has constantly boosted, reaching a value of 270 billion dollars in 2007.