Our Production Process Flow
Our production process is designed to deliver consistent quality, efficiency, and reliability at every stage of envelope manufacturing. From precision folding to rigorous final inspection, each step is carefully controlled to ensure that every product meets our exacting standards. This streamlined workflow allows us to maintain high productivity while upholding the level of craftsmanship and quality our customers trust.
Folding
1Printing
2Window Patch Application
3Gluing & Sealing
4Drying & Curling
5Quality Control & Inspection
6Packing & Boxing
7Our Machinery and Equipment
At our production facility, we utilize a range of advanced machinery to ensure precision, efficiency, and high-quality output. Here is a look at some of the key machines that power our production processes:
Web Fed Equipment & Blank Fed Equipment
Key machinery used (W&D, FL Smith Machines)
● Eleven primary converting lines/machines (+2 under commissioning)
Capacity of our converting equipment is 1.4 billion units
● Monthly capacity to produce 110 million units
● Additional monthly capacity of 24 million under commissioning
Our Total Quality Management
● In-Process Quality Control (IPQC): Continuous monitoring and testing throughout production to identify issues early.
● Final Quality Inspection: Comprehensive checks after production to ensure that all finished products meet required specifications.
● Quality Awareness: Building a quality-conscious culture through workshops and rewards for consistent quality performance.
● Continuous Improvement: Regular reviews of quality issues with feedback loops to improve processes.
Acceptance Quality Limits (AQLs)
Definition: AQLs are the maximum acceptable defect rates in a batch of products.
AQL Levels Used:
- Critical defects: 0.1%
- Major defects: 1.5%
- Minor defects: 4.0%
Inspections are done on two levels L1 and L2
Sampling Procedures: We conduct batch-wise sampling based on to inspect product quality and ensure defect rates stay within acceptable limits.
Inspection Points: Inspection is performed at multiple stages of the process.
An average defect rate of 0.55% (Total Revenue/Returns and inventory adjustments)