How Munky Helped a Client Save ₹23.90 Crores in Laminate Costs?



In today’s competitive FMCG and food industry, even the smallest cost savings can create massive differences in profitability. Munky Packaging Machine has always focused on efficiency, accuracy, and savings, not just in manpower but also in packaging materials. This case study showcases how Munky helped one of its clients save a massive ₹23.90 crores just by optimizing laminate usage through intelligent packing machine solutions.

The Client’s Challenge

The client, a major snacks manufacturer based in North India, was facing three key issues:-

  1. Excessive laminate wastage due to imprecise sealing and pouch length variations
  2. Overfilling of pouches, resulting in product giveaway and profit loss
  3. Increasing complaints from distributors regarding inconsistent pouch weights and sizes

The company had been using outdated semi-automatic machines that were not only slow but also wasteful in their laminate consumption.

Munky’s Approach: Analysis + Automation

At Munky Packaging Machine, we don’t just sell machines; we provide tailored solutions.

Step 1: In-Plant Audit

Our technical team conducted a full plant audit and analyzed:

  • Pouch design and laminate roll width
  • Current wastage per pouch (approx 1.5 cm extra per seal)
  • Daily production volume
  • Variability in weight filling and machine downtime

Step 2: Recommendation

We recommended our Automatic Chips Packing Machine with:

  • Servo-driven sealing jaws for precise laminate usage
  • Multi-head weigh filler for accurate weight-based filling
  • Touch panel for pouch size settings to reduce manual error
  • Nitrogen flushing system to extend shelf life and reduce complaints

The Numbers That Matter: ₹23.90 Crores Saved

By switching to Munky’s advanced packaging system, the client saw immediate improvements:

Metric Before Munky After Munky

Laminate Wastage per Pouch | 1.5 cm0.3 cm

Average Production per Day | 1.5 lakh pouches 1.8 lakh pouches

Annual Pouch Volume | 5.4 crore+6.3 crore+

Laminate Savings per Pouch | ₹0.40₹0.40

Total Annual Savings — | ₹23.90 Crores

Yes, saving ₹0.40 per pouch multiplied by over 6 crore pouches a year led to a staggering cost reduction of ₹23.90 Crores annually.

Key Machine Features That Enabled This

Here’s how Munky’s machine made the difference:

Precise Sealing System

Our machines use servo-based sealing jaws that maintain consistent temperature and pressure, minimizing laminate overuse.

Weight-Based Filling

Using a multi-head weigh filler, each pouch received the exact programmed net weight, not 1 gram extra. This eliminated the need for overfilling and saved product material.

Pouch Customization

Switching pouch size and weight could be done in just 2 minutes, ensuring minimal downtime during batch shifts.

Batch Coding & Nitrogen Flushing

Nitrogen flushing extended shelf life and reduced chip breakage, while batch coding ensured traceability and compliance with regulations.

Client Feedback

We didn’t realize how much money was leaking through our packaging line. Munky’s team not only provided us with a world-class packing machine but also helped us implement a system that will save us crores every year. We’ve now upgraded all 6 of our lines with Munky machines.
Operations Head, Snacks Brand, NCR

Why Munky Machines Make a Difference

At Munky Packaging Machine, we blend Indian engineering with international standards. Our machines are:

  • Manufactured with high-grade stainless steel
  • Designed for 24/7 operation
  • Supported by PAN India service network
  • Customizable for any food product — from chips, namkeen, to tea and pulses

Whether you’re a startup or a large-scale snacks producer, our goal is simple: maximize your efficiency, minimize your cost.

Want to Save in Crores Too?

Let’s talk. We’ve helped brands across India reduce packaging waste, improve speed, and increase profitability. If you’re using outdated packaging systems or facing laminate loss, it’s time to upgrade.

👉 Call us at +91 9599919442
👉 Visit www.munky.in
👉 Get a Free ROI Report customized for your business

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