ARMED with the latest technologies and innovations from around the globe, the Genting Sanyen group is moving forward confidently to build on its vision of a new generation box plant, and lifting packaging standards in Malaysia to the next level.
Malaysia's largest integrated paper and corrugated carton manufacturer had since venturing into the downstream packaging business in 1998 spent more than RM450mil on its two corrugating plants to make them among the most modern plants in the region. The plants are located at Kuala Langat in Selangor, and Prai in Penang.
It had previously invested close to RM1bil on its paper mill division since 1992, when it set up the paper mill in Kuala Langat. Today, its paper mill is regarded as the most ad- vanced in Malaysia, consistently achieving efficiency levels in excess of 95% and producing more than 240,000 tonnes of paper a year.
Genting Sanyen Industrial Paper Sdn Bhd packaging division general manager Ling Eng Kheat told Star Business: We source for and invest in the best technologies in the world because were building our plants for the future, where technology would be the driving force.
Among its investments are one of the fastest corrugators in the world, capable of a maximum speed 450m/min (compared with 80, 90 or 100m/min for older plants); and two Bobst Masterflexes printers capable of brilliant six- and eight-colour flexographic printing at a speed of up to 10,000 cartons per hour.
According to Ling, the two printers costing RM12mil and RM15mil respectively, use water-based ink and thus are very environmental friendly and cost effective for high volume requirements.
Its two box plants, each with an installed capacity of 120,000 tonnes of cartons a year, are touted to be among the most highly automated in the world. An extensive series of conveyors moves work-in-progress from one machine to the next automatically. The seamless production process is managed by an integrated enterprise resource planning (ERP) system, which controls major tasks such as sales ordering, production planning, material management and financial accounting.
Once the goods are finished, the automatic storage and retrieval system (ASRS) takes over and manages the logistic of finished goods storage and delivery. The high-tech ASRS commissioned by Komatsu Japan costs RM15mil.
Due to the integrated nature of operations, Genting Sanyen is able to give customers more value added, as its paper mill can jointly develop paper for particular needs of customers, such as a special coated 200g paperboard.
About 85% of the materials for the box plants are derived from its own paper mill. The balance used for special applications is imported.
In its quest to provide more value added and packaging innovation to its customers Genting Sanyen entered into a smart partnership with OTOR France, a global leader in innovative packaging systems, early last year. It was appointed exclusive licensee for the OTOR system in Malaysia, Singapore, Thailand and Vietnam, and non-exclusive licensee for the China market.
The deal included the transfer of technology to Genting Sanyen, including design and know-how for OTORs packaging systems, and distributorship of OTOR machines, such as the OTOR case erectors, to clients.
The OTOR is a system that designs packaging, enabling the use of lower quality packaging material yet providing similar strength. Corrugated board production quality and factory productivity are both limited by the vibrations and pressures that the board endures during the corrugating process. The Push Pull processes developed by OTOR eliminate these drawbacks.
The first project for OTOR case erectors was with Nestle Malaysia for soft pack packaging. The company is now following up with another five of its major customers and is in the final stages of negotiation.