Perfect Packers Strengthens Operations with Automation and Expanded Capabilities
Agra-based Perfect Packers, a leading corrugated packaging specialist for the footwear industry, was established in 1995 by brothers Ankur and Vikas Mahajan. Beginning with a modest production capacity of around 500 shoe boxes per day, the company has grown significantly over the years. In 2014, it relocated to a 20,000-square-foot facility in Artoni, and today boasts a daily production capacity of approximately 1.25 lakh corrugated shoe boxes.
Perfect Packers offers end-to-end packaging solutions for the footwear sector, including tissue paper, outer cartons, hand tags, and box labels. The company caters to a diverse clientele, supplying both domestic and international brands such as Zara, Bata, Skechers, Asics, MNG, Hush Puppies, Gent, and Spykar. In addition to serving the Indian market, the company exports corrugated shoe boxes to Bangladesh, with occasional orders from Thailand and South Africa. Since 2018, it has also expanded into the production of rigid boxes.
While the company attracts interest from emerging Indian footwear startups, it maintains a minimum order quantity of 5,000 units. Nonetheless, it has successfully executed large-scale orders exceeding 50,000 boxes for brands like The Souled Store and Frido. Its primary markets include major footwear hubs such as Mumbai, Delhi-NCR, Bengaluru, and Chennai. The company has also been recognized by the Confederation of Indian Footwear Industries for excellence in corrugated shoe box packaging in Agra.
In line with its growth strategy, Perfect Packers recently installed a DGM Technocut 1050S automatic diecutter, complementing its existing fleet of 11 manual diecutters. According to Vikas Mahajan, the new machine has significantly enhanced operational efficiency, delivering a strong boost to productivity and overall performance.
The company’s production infrastructure includes four five-color German Planeta presses, a flexo reel printing machine from Prakash, and a four-color Heidelberg Speedmaster with coater, known for its high print quality and productivity. Additional equipment includes machines from Ample and Natraj for corrugation, two lamination units from Youbond Machinery, and a Konica Minolta digital press for label production. The facility is also supported by ancillary equipment for cutting, varnishing, and logistics.
Despite its robust setup, the plant remains labor-intensive, employing around 300 personnel. Mahajan highlights challenges such as the shortage of skilled manpower and the need for greater automation. The company aims to address these issues by increasing its focus on automated technologies to improve efficiency and streamline operations.
The business also faces occasional challenges related to payment cycles and credit limits with buyers. Additionally, global geopolitical tensions, including the Iran war, have contributed to rising raw material costs, particularly for ink, paper, and lamination supplies.
Perfect Packers sources duplex board, art paper, and kappa board in various grades from both domestic and international suppliers. Its procurement network includes several Indian mills such as Siddharth Papers, Devpriya Paper Mill, Sahota Paper Mill, Genus Paper Mill, Divya Shakti Paper Mill, Edicon Paper Mill, JK Ultima, Vishwanath Paper & Boards, Chadha Paper Mill, United Paper Mills, Shree Venktesh Paper Mills, Paswara Papers, KM Papers, Cheema Papers, MLM, Line Craft, Tirupati Kraft Paper, and Paper Vintage Point. A dedicated quality control team ensures consistency across the wide range of materials and grammages used in production.
