We are CHANGING our approach to plastic manufacturing

Sai Group’s endeavour is to build a responsible business that reduces our environmental footprint while providing social value

  • We look forward to achieving half of our carbon neutrality target by 2030.
  • Extended producer responsibility strategies are a major part of our plans moving forward
  • We aim to provide value added services to our customers in a rapidly changing sector.

Small steps make a BIG difference

Our road to transformation will require a paradigm shift in how we structure our strategic outlook

  • Our priority for the near future involves developing sound understanding of financial, environmental, and social compliances to grow our market outreach.
  • Our roadmap is key to achieving our vision for a prosperous, inclusive and sustainable future

Vision

View Roadmap

The importance of INNOVATION in a changing world

Technological changes have ushered a new age for sustainable growth

  • We are always looking forward to employing cutting edge technology to help maximise resource efficiency.
  • Our exciting upcoming digital inventory management system will significantly optimize our supply chain strategies.

Operations

A BUSINESS that reduces our environmental footprint

Our vision is to explore changing technologies and practices to give our business a competitive and sustainable edge by being at the forefront of circular economy developments. We also hope to explore the pharmaceutical industry and implement strict manufacturing standards to ensure prime quality throughout our range of products. Founded in 2020, SAI FuturePlast is our pathway to this vision. Based in Indore, our manufacturing function will aim to address critical developments within sectors in sustainable packaging. It will also cement our growth strategy to encompass an exploration into newer industries.

The Plastic Industry is undergoing an unprecedented change.
Here’s some highlights:

Landfills in urban areas around the world are approaching breaking point

Within the next two decades there will be more plastic than fish in the ocean

Plastic packaging is shifting its approach to incorporating post consumer recycling processes

In several countries around the world, single use plastic is being phased out

The plastic packaging industry grows and will continue to grow by nearly 3.5 % for the next decade

Global environmental problems require critical solutions and participation by small and medium scale enterprises to change our future

As an organisation, we strive to achieve a vision for the better.

BRAND PLACEMENT

  • As a medium scale enterprise we cater to the fast moving consumer goods industry
  • We aim to have a more diverse portfolio of existing products to grow our company
  • We put prime emphasis on the quality of our products and the efficiency of our improving supply chain.
  • Using our digital inventory management system, we will secure our place as an innovative brand focusing on employing the best technology for supply chain management.
  • We constantly upgrade our manufacturing technology to keep up with the changing efficiency of production practices at a global level.
  • There is a wide scope for growth within our target sectors over the next decade.
  • We hope to explore that scope keeping in mind efficiency and time management.
  • With our upcoming GMP certifications, we hope to improve our reach to global markets and accessibility to niche manufacturing sectors.
  • Our future plan involves diversifying into the pharmaceutical packaging sector.

Roadmap

SAI Enterprises starts in a rental premises in Dehradun. We take possession of 3,000 sq m of space—Integrated Industrial Estate Pantnagar, UK.

2004

2006

SAI Enterprises starts in a rental premises in Dehradun. We take possession of 3,000 sq m of space—Integrated Industrial Estate Pantnagar, UK.

1st multicavity-Auto deflashing-extrusion blow molding line is set up with a capacity to produce 45,000 200 ml bottles a day

2007

2009

1st injection blow molding machine is commissioned. Six more lines get added within the next 4 years till 2013.

Subsequent expansion in injection molding machines for caps and closures takes place. 11 machines are added to boost capacity

2014

2016

We diversify into manufacturing of laminated tubes in Pantnagar with a fully automatic line

Greenfield project commissioned at Tezpur, Assam. 4,000 sq m of land with overall increased capacity in the IBM, EBM , and injection molding.

2017

2020

Total capacity in injection molding reaches— Integrating digitised inventory management system and starting application for certifications

Acquired 8,000 sq m of land in Indore, MP, which is scheduled to be commissioned for production in 2023.

2021

2022

Integrating digitised inventory management system and starting application for certifications

Aim to start production at the Indore plant.

2023

2025

We aim to double our capacity across our product portfolio

We aim to double our capacity across our product portfolio

Aim to expand our renewable energy usage to 30% of all functioning.

2027

2030

We aim to expand our renewable energy capacity to 50% of all functioning. Half of our granules used will be food grade post consumer recycled waste.

Our OPERATIONS

TECHNOLOGY

  • INJECTION MOLDING

    • 30 functional machines ranging from 150 Ton to 350 Ton capacity
    • A total capacity of three million caps / closures per day
    • A broad range of moulds from 8 cavities to 32 cavities with fully equipped hot runners and in mould closing systems
    • Materials used - HDPE, LDPE and PP
  • INJECTION BLOW MOLDING

    • Seven sets of machines ranging from 450 Tons to 650 Tons
    • Capacity of 500,000 bottles per day
    • Stock keeping units ranging from 8ml to 300 ml for bottles, jars, dispensers
    • Materials used - HDPE and PP
  • EXTRUSION BLOW MOLDING

    • 2 sets of machines with multi cavity and auto deflashing provisions.
    • Capacity of 50,000 bottles per day from 300 ml up to 1 litre.
    • Materials used - HDPE and PP

SUPPLY CHAIN

We run our own proprietary digital inventory management system

Raw material purchase

Issue for mixing granules with masterbatch

Mixing process for colouring

Issue for shiftwise allocation to machines

Production process for finished goods

Quality inspection

Packing and labelling of goods for storage

Dispatch of goods to customers as per requirements

VALUE CREATION

We go beyond regular business practices to create value for our partners keeping in mind sound business ethics

FINANCIAL
VALUES

INPUT

  • Prudent Account Management——Financial management and accountability are key in our financial value system
  • Investment Planning—As a growing business we plan our finances to start the process of achieving our aspirations

OUTPUT

  • Sustained Revenue

OUTCOME

  • Optimised Capital Structure
  • Enhanced Balance Sheet

MANUFACTURING
VALUES

INPUT

  • Installed Capacities—We have 2 functioning plants with a 3rd plant being built. Each project has increased our standing capacity and opportunities for product diversification and scaling.
  • Reliable Supply Chain and Production Processes—We partner with dependable suppliers and have taken constant steps to maintain and improve our manufacturing flow.

OUTPUT

  • Managed Category Production
  • Diversified Product Portfolio—12 different caps and 45 different bottles

OUTCOME

  • Reduction in wastages and rejection
  • High quality end products
  • Constant expansion and growth

INTELLECTUAL
VALUES

INPUT

  • Upskilling the Workforce—We provide a range of training to our workforce on supply chain management and manufacturing practices
  • Digital Initiatives—We are working towards implementing a digital inventory management system.
  • Newer Technology Implementation—We constantly upgrade and train our workforce to use newer technology and machinery for manufacturing.

OUTPUT

  • Newer products manufactured
  • Enhanced storage mechanisms

OUTCOME

  • Business Excellence
  • Increasing Intangible Value Worth
  • Increased Transparency in the Supply Chain

HUMAN
VALUES

INPUT

  • Diverse Workforce—Half of our permanent workforce in the Pantnagar plant are women. For our other manufacturing locations we aspire to implement this strategy as well.
  • Capability Building—We incentivise our workforce by providing them with a dynamic bonus structure and assist them in upskilling for employment promotions
  • Health and safety practices keeping in mind laws and regulation

OUTPUT

  • Increased Productivity
  • Employee Wellbeing
  • Safe Workplace

OUTCOME

  • Higher Performance Culture
  • Aspirational Quality of Life
  • Better Employer Brand

ENVIRONMENTAL
VALUES

INPUT

  • Energy Use—We are targeting to reduce our carbon footprint through energy use by 50% by 2030.
  • Waste Management—We have achieved a significant reduction in production waste by reusing rejected products and granules with our machine grinders. We aspire to use half our granules from post consumer recycled processes by 2030.
  • Sustainable Technology Implementation—We are working on integrating all electric machinery throughout our manufacturing facilities to reduce our environmental footprint by reducing dependency on fossil fuels.

OUTPUT

  • Waste Reduction
  • Energy Efficiency
  • Greenhouse Gas Reduction
  • Recycled Material

OUTCOME

  • Reduced Environmental Footprint
  • Sound Sustainability Roadmap
  • Adherence and Compliance with Changing Environmental Regulations

In compliance with Extended Producer Responsibility

OUR COMMITMENT

  • Extended Producer Responsibility (EPR) is leading to a paradigm shift in the plastic manufacturing industry.
  • As a company we realise the impact of the plastic packaging industry on the environment.
  • We hope to minimise our impact on the environment and look forward to restructuring our business practices to meet emerging EPR compliance mechanisms
  • As a business we stress on the need for transparency in building a more sustainable supply chain.
  • We are working towards responsible sourcing and waste minimisation practices that will help us significantly reduce our environmental footprint.
  • We are committed to using food grade recycled material for half our production capacity by 2030.
  • To achieve this we are constantly evaluating innovative newer technologies that will help us reach our sustainability goals.

CERTIFICATIONS

Our functioning plants at Pantnagar, Uttrakhand, and Tezpur, Assam are ISO 9001:2015 and GMP (UKCert) certified.

ISO 9001

ISO 9001:2015

Certified.

The quality of our products and services is a top priority for us. We practice and demonstrate quality practices that meet customer and applicable statutory and regulatory requirements. We aim to enhance customer satisfaction through the effective application of the system, including processes for improvement of the system and the assurance of conformity to customer and applicable statutory and regulatory requirements.
ISO 22716

GMP

Certified.

We make sure that our products are consistently produced and controlled according to quality standards. Good Manufacturing Practices (GMP) is an initiative of the WHO. The main aim of GMP is to see to it that the products are good and sufficient for utilization after the final outcome. GMP governs the product at each and every step of manufacturing. By getting certified we ensure products are consistently produced and controlled to the quality standards appropriate to their intended use and as essential by the marketing authorization (MA) or product specification.