Kumar Labels expands Greater Noida facility

Founded in 2007 by Anuj Bhargava, Kumar Labels has become one of the leading converters in India’s label printing sector. Headquartered in Greater Noida, the company expanded to a new, 50,000 sqft facility to consolidate four factories. With two new flexo lines, multiple inspection slitters, a new test lab and all LED UV presses, Kumar Labels’ new facility is claimed to be India’s largest and most sustainable label production infrastructure under one roof.

The growth journey

Entering a market already populated by established players required a distinct strategy. From the outset, Bhargava recognized that competing on price wouldn’t suffice. The focus, therefore, was on building capabilities that could deliver superior products and meet the evolving demands of brand owners, particularly in challenging segments like alcoholic beverages and FMCG.

‘In FY24-25, we launched innovations such as raised foil and silk fabric on PS labels for the first time in India to cater to the demands of brand owners,’ Bhargava says. ‘Our new facility is equipped with machines that enable us to innovate and produce something new in India.’

The newly expanded facility houses a water-based coater and a hot melt line. Both lines are equipped with a contactless adhesive measurement system from NDC. The factory, which was earlier used as a warehouse, also stores release liners. Currently, the company manufactures 8 million sqm of labelstock, and its total manufacturing capacity stands at 18 million sqm.

Technology that matters

Technology is the cornerstone of Kumar Labels’ success. ‘We believe in Toyota’s principles of “Autonomation”. We believe in using simple, quick-to-set-up, flexible capability to do any job without hardware change, easy-to-operate and low-cost machinery for production. This reduces turnaround time and cost of production, enables shorter runs and more value addition, reduces wastage and improves quality,’ shares Bhargava. ‘Our IT team implemented a new ERP system that enabled monthly reconciliation of materials accurate to 99.6 percent. We also introduced automatic order updates for our customers.

‘Our operations team improved efficiencies from running 280mm wide presses to 410mm ones,’ adds Bhargava.

From the outset, Kumar Labels has carefully selected the appropriate technology. Rather than starting small and gradually scaling, the company made significant initial investments in state-of-the-art printing technology, signaling its intent to compete at the higher end of the market from day one.

“There is considerable demand for premiumization across all categories. With premium packaging, perceptions of a brand are changing and giving a kick to the market”

When Bhargava decided to enter the printing and packaging industry, he identified a gap between customer demand and the technology offered by label converters. Bhargava recalls: ‘As I researched, I concluded that major customers demanded short runs regularly. However, the label printers I spoke to suggested investing in a rotary flexo press, which is great for larger volumes, but not for short-run jobs.’

This led Bhargava to decide to invest in an intermittent letterpress from a Korean manufacturer, Bangsung. Having been impressed with the results, he purchased another one in 2009.

The company has consistently invested in advanced printing and finishing equipment, maintaining a modern fleet capable of handling complex requirements and ensuring high-quality output. ‘Now is the time for a combination of technologies. The first and last units of my letterpress utilize flexo technology, while the other six units of the machine are letterpress. We customize every machine. In addition, we have a lot of off-line capacity using eight flatbed converting machines,’ he explains.

The company also added several silk-screen printing machines, slitting, hologram decorating and inspection machines. It operates an Esko CDI digital imaging and processing system for both pre-press and flexo and letterpress platemaking in-house, which was added in recent years.

Technology is fundamental to Kumar Labels’ success and is evident in its daily operations. ‘It’s not only about what technology we are choosing for printing, but also about choosing the right technology to make our lives and jobs easier and simpler,’ comments Bhargava. ‘Previously, we handled all the administrative and operational tasks manually. Individuals had to stand in queues to make their requests, and there was no way to track them. We now have automated processes and have trained our personnel to utilize the system. You will see QR codes displayed in all prominent areas for various tasks, including visitor entry forms, finance and HR-related issues such as POSH (Prevention of Sexual Harassment), among others.

‘Initially, the team was reluctant to use the system, but as time passed, the employees figured out the ease of the process, and now everyone is using it,’ shares Bhargava.

Sustainable initiatives

Demonstrating a commitment to sustainability and efficiency, Kumar Labels’ in-house coating team introduced the rPET-based labels (face and liner) in 2024 to improve the PSA label sustainability quotient by 90 percent and reduce dependence on imports.

“Demonstrating our commitment to sustainability and efficiency, we transitioned all our flexo presses from conventional UV to UV LED systems, which resulted in a one-third reduction in power consumption”

The company also transitioned all its flexo presses from conventional UV to UV LED systems. ‘This shift resulted in a one-third reduction in power consumption, elimination of ozone emissions, and increased press speeds by at least 20 percent,’ notes Bhargava. ‘The UV LED systems also feature longer lifespans, reducing maintenance and replacement costs.’

Bhargava’s proactive approach included personal evaluations of power consumption, confirming substantial energy savings. The company uses a water-washable 1.14 plate system from Japan, further aligning with its sustainability goals.

To ensure impeccable print quality, Kumar Labels installed the Guardian OLP off-line proofing and inspection system from Baldwin Technology. This system enables the detection of pre-press defects, reducing waste and enhancing productivity.

The company also develops recyclable barrier-coated and poly-coated liners, aiming to improve recyclability and reduce costs. These initiatives demonstrate Kumar Labels’ dedication to environmental responsibility.

Future forward

With a significant involvement in manufacturing alcoholic beverage labels, Bhargava observes a considerable demand for premiumization across all categories, and a clear trend to ‘stand out’ rather than appear as a ‘me too’ brand. With premium packaging, perceptions of a brand are changing and giving a kick to the market.

Kumar Labels is a one-stop shop for its customers, producing materials, labelstocks and label applicators. Bhargava summarizes, ‘Therefore, we can offer our customers a better price. Our focus on innovation, fast and agile presses and ancillary equipment, reliable service, price and our family history of working in the industry differentiate the company.’

The company adds value to its luxury liquor labels with embossing effects created using foils and coatings. These are made with UV coatings on its flexo presses and automated silk-screen machines.

The company also employs a graining machine to add unique textures to paper labels for an engaging tactile experience. It devises every new visual and haptic possibility to set luxury brands apart from their competitors. The company’s alcoholic beverage clients include Beam Suntory India, Jim Beam and Teacher’s whiskey makers, Captain Morgan, Oak Smith, Indri, Camikara, to name just a few.

Being in the labels industry for over 15 years has given the company the advantage of understanding the needs of the competitive alcoholic beverage industry. This, in turn, helps it guide its customers about legal mandates for approvals, trade requirements for labels and more.

Workforce development

Bhargava believes in continuously training employees. He trained over 1,200 people in label converting, but acknowledges that skilled employee retention is a problem in this industry.

‘Since lack of skilled workforce is a major challenge in our industry, people who have attained competence get poached very easily,’ says Bhargava.

He plans to create a relative surplus of skilled resources through a structured label training program. It will be available at three levels of competence, combining course materials and hands-on training on modern equipment at his plant.

Designed for operators, senior operators and label production management, each level will be priced nominally. The plan is to attract young resources from ITIs (Industrial Training Institutes) needing employment at the most basic level.

Kumar Labels exemplifies how strategic foresight, technological innovation and a commitment to sustainability can drive success in the label printing industry.

By continuously adapting to market demands and investing in infrastructure and human resources, the company has led the sector toward a more sustainable and efficient future.

Kumar Labels orders third Starflex from NBG at Labelexpo India 2024

The Starflex narrow-web flexo press has an in-line gravure station, allowing for high-quality printing with depth and detail. This feature enables Kumar Labels to incorporate intricate designs, special inks, or coatings directly in-line, making it suitable for premium labels. Its LED UV curing system offers faster drying times while reducing energy consumption. LED UV provides consistent curing quality at lower temperatures.

‘Our 10-color Starflex meets Kumar Labels’ high standards, ensuring flexibility and responsiveness to their clients’ needs,’ says Nitin Garg of NBG. ‘We’re grateful for the trust Anuj Bhagava of Kumar Labels has placed in us, inspiring us to continuously elevate our offerings and deliver machines that match the highest print quality and efficiency standards. Here’s to a successful partnership that drives innovation and achievements in the label printing industry.’