Every online order or supermarket purchase goes through a complex journey—from factories and warehouses to trucks, protected by a simple cardboard box. Although we rarely pay attention to it, without this packaging, goods could be damaged, delayed, or not reach the consumer at all.
As manufacturing and e-commerce sectors expand in India, the demand for reliable, durable, and eco-friendly packaging is growing. Udaan Paper Industries, based in Indore, responded to this demand by transitioning from manual production to automated processes.
Automation and Production
Today, the company produces about 5 million recyclable corrugated boxes monthly. This helps businesses receive quality packaging faster while reducing waste and promoting the move away from plastic.
For a long time, India's corrugated packaging industry heavily relied on manual processes, which often resulted in inconsistent quality, slower production, and difficulties meeting growing demand. At the same time, companies were seeking eco-friendly alternatives to plastic.
A New Phase of Company Development
For Yash Bakliwala, Managing Director and Chairman of Udaan Paper Industries Limited, this represented an opportunity. He noted that India's consumption and production economy was growing rapidly, but the packaging industry remained fragmented and dependent on manual labor. 'We saw a clear gap between the rising demand for high-quality packaging and the industry's ability to supply it consistently. Businesses were also looking for sustainable alternatives to plastic. This inspired us to create automated manufacturing facilities capable of producing recyclable paper packaging quickly, consistently, and in large volumes,' he stated.
Although Udaan Paper Industries has roots dating back to 1986, the new phase of growth began in 2021 after the current group of promoters took over management, focusing on automation and eco-friendly packaging. Their goal was to solve three long-standing industry problems: inconsistent product quality, production delays, and heavy reliance on manual labor. Furthermore, they aimed to make recyclable paper packaging a practical substitute for plastic.
Manufacturing Capacity and Processes
Udaan currently operates two fully automated production sites: one in Pitampur, Madhya Pradesh, and the other in Kanpur, Uttar Pradesh. These factories supply corrugated packaging to businesses across North and Central India.
Inside the production workshops, the process begins with giant paper rolls. These rolls pass through automated corrugating lines where multiple layers of paper are glued together to create strong corrugated sheets capable of withstanding transportation. The sheets are then cut, printed, folded, and stacked before being transformed into finished boxes of various sizes.
Yash explains that automation makes the entire process faster, more precise, and highly stable. Unlike traditional production, where much depends on manual handling, automation allows every box to be produced to a uniform quality standard, minimizing material consumption and increasing efficiency. 'Our goal is to provide packaging that offers consistent quality, is produced faster, and is delivered to customers on time,' he emphasized. 'Automation helps us improve production planning, reduce material waste, and support the transition from plastic to recyclable paper packaging.'
Staff Role and Logistics
Despite having advanced equipment, people remain a key element of the operation. Quality control, machine monitoring, maintenance, and shipment planning are handled by Udaan teams. Yash notes: 'Technology increases efficiency, but it is skilled employees who ensure quality and reliability.'
The company employs around 100 people across its two plants. As automation expands, many employees have transitioned from heavy physical manual labor to more specialized technical roles. 'Every new machine requires trained operators. We view automation as an opportunity to upskill our employees, not replace them,' adds Yash.
The monthly output of 5 million boxes makes this packaging an integral part of India's supply chain. The installed capacity of the two automated facilities is 30,000 tons per year. The packaging is used in sectors such as FMCG, food processing, dairy, beverages, textiles, and consumer goods, and the company continues to expand into pharmaceuticals and e-commerce.
Technology also plays a role beyond production. GPS-equipped vehicles, optimized route planning, and improved production scheduling ensure timely delivery of packaging, allowing client production lines to operate without interruption. 'Our role doesn't end when the box leaves the factory,' says Yash. 'By strengthening both production and logistics, we help clients improve inventory movement, reduce order fulfillment times, and build more efficient supply chains.'
Future Prospects of the Company
With two automated factories operating at full capacity, Udaan is already planning its next stage of growth. The company intends to become a comprehensive provider of sustainable packaging solutions, expanding into related paper products, including paper bags. This will allow businesses to source a wider range of eco-friendly packaging from a single partner.
In addition to manufacturing, Udaan plans to strengthen its capabilities in technology-driven logistics and reverse logistics to help clients optimize inventory movement and create more efficient supply chains. The company is also considering entering international markets, including the USA, UK, North America, Latin America, and Australia, where the demand for environmentally friendly paper packaging is growing.
Yash is convinced that automated production, technology-based logistics, and sustainable packaging will help Indian enterprises compete globally. 'As India's manufacturing, e-commerce, FMCG, and organized retail sectors continue to grow, automation will become essential. Future packaging companies will compete not only on price but also on quality, speed, stability, sustainability, and supply chain reliability. Automation will help Indian manufacturers compete globally. Our vision is to build one of India's most reliable automated packaging companies.'
