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Aluminium tubes 15 Billion* Laminated tubes 14 Billion* Extruded plastic tubes 7 Billion*
* - Company estimates Tubes as a form of packaging began with aluminium tubes all over the world. Since the advent of laminated and extruded plastic tubes in the packaging arena as new packaging form two decades ago, these tubes systematically began replacing aluminium tubes worldover. By adopting extruded plastic
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High-end lamination technology Knowledge of Barrier Properties OEM business model Highest standards of quality and manufacturing systems Expanded product portfolio to a common customer profile Leveraging relationships to service customers Tapping the global customer base of Essel Propack to expand PIPLs customer base
The growth in this packaging form is being fuelled by the FMCG sector and Pharma sector. There is a growing demand for innovative packaging and the export potential is immense. Packaging attractiveness will be a key driver of the branding strategy in these sectors. At present Indian Pharma industry is moving up the value chain bulk to generic to formulations. Also there is a renewed focus on Food Processing Industry in India coupled with retail
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The Medical Devices industry offers tremendous growth opportunities. This is a recession-proof industry. Moreover, this industry is not yet developed in Asia, which is a highly populated geography. Globally, it is a fragmented industry with fragmented buyers. Also there are high entry barriers such as capabilities for Design & Prototyping and FDA approvals which makes it difficult for companies to enter with ease. Contracts and contacts with customer, which takes considerable time to develop, play a significant role in growth in this industry. By the very nature of the products and the industry, there is a need for high level of innovation. Essel Propack and Tacpro have the requisite knowledge and competence to drive the Medical Devices business on a higher trajectory of growth. The management of Tacpro at the time of acquisition continues to lead the business.
Strengths
Strengths of Essel Propack
Knowledge Over the years Essel Propack has acquired a huge knowledge base in diverse aspects such as polymers, polymer processing, manufacturing systems, markets and logistics and sourcing. This knowledge will be the backbone for driving its growth engines along the three revenue streams namely Laminated Tubes/Extruded Plastic Tubes, Specialty Packaging Materials and Medical Devices. All the knowledge is documented and there is an efficient system for transfer of knowledge between the units across the world.
Creativity & Innovation Creativity & Innovation play a critical role in keeping the Company ahead of competition and to drive continuous growth. All the three revenue streams, although with different business environments, have a strong base in Creativity & Innovation. This aspect has not only led to creating new products, but also in identifying new product applications or discovering new business categories. This has also led to identifying new raw material mix, improvising on existing
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Leadership Being a global Company present in all major geographies, the Company understands cultural sensitivities of any geography. Leadership is well versed in leading a culturally and ethnically diverse workforce comprising over 20 nationalities, towards the organisational goal.
Dedicated and Passionate People The Company has a strong team of knowledgeable, dedicated, focused and object driven workforce. This Human Capital is the foundation on which the Company has been built. The workforce is continually nurtured, motivated, trained and developed.
Three revenue streams - Laminated Tubes / Extruded Plastic Tubes, Medical Devices and Specialty Packaging Materials The Company today has three revenue streams namely Laminated Tubes / Extruded Plastic Tubes, Medical Devices and Specialty Packaging Materials. Earlier the Company had only tubes business. To dilute the market risk, the Company forayed into Medical Devices and Specialty Packaging Materials which have perfect synergy with the Companys tube business and also has great growth potential.
Largest manufacturer of Laminated Tubes globally Global market share 32% Manufacturing facilities in 12 countries through 19 plants Integrated Process Technology Customer profile include all reputed brands in every market multi-national, national, regional and local brands New Application opportunities in Hair Care, Food and Pharma Minitubes a proprietary technology for making small size laminated tubes Inviseam technology, a breakthrough in laminated tubes
Shared Vision across the Value Chain Your Company always firmly believed in a shared vision, be it with the customers, employees, vendors, shareholders or society at large. This has resulted in a close and intense partnership between the Company and all its stakeholders.
Strength in Process Technology & Efficient Manufacturing Systems One of the key strengths of the Company is in the use of state-of-the-art process technology. The technology is continually evaluated and upgraded to keep the Company ahead of the competition. The Company deploys time tested and efficient manufacturing systems and processes such as Six Sigma, HMP (Harmonised Manufacturing Policy) and GMP (Good Manufacturing Practices).
Currently manufacturing in 3 countries UK, India and USA with a unit in Poland to be commissioned in Q3 / 2007 Expanding into new geographies such as the USA and Poland Strong customer base in the UK and Europe through Arista Tubes, UK
Global Footprint and Relationships The Company is present in all the major geographies of the world. This was the outcome of the Companys
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State-of-the-art technology, unmatched product development expertise Strong relationships with a highly diversified, blue chip customer base Currently focused on Food and Personal Care Specific plans to move up the value chain - Pharma and convenience packaging Leverage on Essel Propacks knowledge of polymers and polymer processing including co-extrusion and blown film knowledge
Setting the stage for broad-basing the business with addition of new product lines, for sustainable & improving revenue and profit growth in the coming years The new initiatives such as Medical Devices and Specialty Packaging Material business in 2006 were a step in this direction. The Medical Device business opens up a new frontier, leveraging on Essel Propack's core competencies of polymer processing and complementing with the design & prototyping capabilities. We see robust growth opportunities here, which will take the present product line (catheters) beyond cardiac applications to other areas. Specialty Packaging Materials is an India-centric business. The business is well positioned to ride on the increasing need for packaging solutions, fuelled by factors such as India becoming the world manufacturing hub for prescription drugs and the retail boom. There are further value propositions to up the value chain in Pharma and exports, which can be easily tapped into leveraging on Essel Propacks capabilities of extrusion lamination.
Two state-of-the-art facilities USA and Singapore Provider of innovative medical device designs, converting ideas into medical device solutions First full-service provider of high quality medical devices specializing in catheters and delivery systems on the West Coast of USA World leader in OEM balloon catheters Focused on design, engineering services and rapid prototyping Customer lock-in State-of-the-art manufacturing base in Singapore A single source solution Company
Opportunities
Expansion of the tube capabilities into higher value segments The thrust was on rapidly expanding our capabilities and footprint with co-extruded plastic tubes. The existing capacity
Turnaround of the acquired businesses in UK and the start-ups in Mexico and Russia The organisation continued to focus on turn around of loss making businesses. By the end of 2006, we were successful in turning around the laminated tube business in UK and Mexico. The extruded plastic tube business in UK has reached breakeven levels by the end of 2006. We aim to sustain these
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Threats
Raw material prices continued to be volatile and unpredictable. While we could get price increase to neutralise the same, we were frequently in a catch-up mode. This, to some extent, did impact the margins during the year 2006. The raw material supply situation is expected to improve with an increase in ethylene capacities projected for mid-2008. Right through 2006, the interest cost, both for US$ and Rupee borrowings, continued to harden.
Opening up new segments in Pharma and Sample segment with Minitube Technology Our success with the new technology continues. Minitube technology has found wide acceptance in Pharma and Oral Care. In Oral Care, it has opened up new price points for customers.
Shuffling the Product and Customer base This was a part of our strategy to improve our margins. Our new thrusts into higher value segments such as skin and hair care had been mentioned earlier. In certain markets, we made similar adjustments by exiting low margin businesses. The churning of product and customer portfolios to some extent did yield results, especially in the laminated tube segment.
Reorganisation of Manufacturing Facilities Essel Propacks efforts are aimed at giving the best value proposition to all its stakeholders. Whether it is setting up a new unit, expanding a unit, downsizing a unit or relocating a unit, the approach had been to rationalize and optimize our resources. In line with the above approach, during 2006, the Nepal plant was closed down. The one-time exit cost was Rs.12 million which has been written off in our books for the year ending December 2006. Similarly, the Company has decided to close down its operations in Venezuela. The demand of the Venezuelan customers will be met by our other units in the region, which have been geared up to meet this additional demand. The entire process and system is in place to meet the demand of Venezuelan market.
Risk : Investment in New Projects The Companys business is capital intensive and involves investments in diverse geographies and markets. This in itself poses risk while investing. Response : A detailed Project Report with analysis of all the performance indicators and the potential risks is always tabled before the Board prior to seeking approval for any project.
Risk : Input Costs including Oil Prices The global price rise of oil was paralleled by polymer prices, which are the essential raw materials for laminated and extruded plastic tubes. Although the crude price has stabilized, the shortage of capacities of ethylene has resulted in continued higher prices of polymers. This situation will continue till mid-2008 when the increase in ethylene capacities are expected to come on stream.
New Organisation structure Taking into consideration the pressing need of the time, the organisation has been recast with changes in the Sales and Marketing organisational structure. The primary business
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Risk : One Product Company The major portion of the revenue of your Company is derived from the manufacture and sale of laminated tubes. This has the potential risk of a substitute appearing on the horizon. Response : Your Company has taken a three-pronged approach to rise above this situation. With your Companys foray into extruded plastic tubes, Medical Devices and Specialty Packaging Materials, three new revenue streams have been created. Thus, the initial step has been taken to reduce dependence on Laminated Tubes business. At the same time, in extruded plastic tubes, your Company has invested in state-of-the-art decoration and printing technology to offer superior graphics for differentiation. Thirdly, to sustain the margins, efforts such as Creativity & Innovation initiatives to develop new laminate structures, enhancement of manufacturing efficiencies including optimal asset utilization and increased agility in our response to market needs have been taken.
Risk : Competition The competition in some product sectors and application sectors have made supply unviable to those sectors. Response : This situation has been countered by constant upgradation of technology and by enhancing the efficiency of operations to effect cost competitiveness. Another major factor for your Companys success, as compared to its peers, is by nurturing the systems in such a way that the Company has a Lean Management structure. To retain the Lean Management, your Company continues to invest sufficient efforts, to retain this edge.
Risk : Commoditisation of Tube Business Customer consolidation and intense competition has led to a commoditisation of the market, leading to lower realisation in certain product and application sectors. Response : Being creative and innovative has given your Company the edge to be ahead of competition by introducing value addons and distinct differentiation in the products. The Company has succeeded in changing the requirement patterns of the market by its innovative products. These include development of innovative polymer structures to preserve content, creation of tubes with in-built security features and making tubes with superior look and feel. These steps have also helped the Company to diversify the customer profile with new product and application groups. The Company always strives to position Essel Propack as the best value supplier.
Risk : Oral care Industry, the prime buyer of laminated tubes Oral care industry has remained the major user of laminated tubes. Any fluctuation in the buying pattern of oral care industry can make an impact on the performance of the Company. The dominance of a few global players in the oral care industry has led to the buying power. Response : To counter the above, new cost-effective laminate structures are consistently evolved. Supplementing these efforts, manufacturing systems are also continuously upgraded enhancing the efficiencies and to raise the output levels. Your
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Risk: Multinational Company Being a multinational Company, your Company is exposed to dynamic economic and market conditions of its operating terrain. Aspects such as changes in consumption pattern, increase in production capacities and regulatory changes in policies relating to imports, tariffs and tax, are unpredictable and hence, are beyond control. Response : Your Company continuously monitors the external environment in all the operating locations and assesses the risk profiles. Effective remedial steps are taken to mitigate the same. Exiting Nepal is one such instance.
forward contracts, the Company hedges its exposure. Moreover, the Company continues to insure its assets through country specific policies. Also, Forex Risk Exposure Policy is in place which provides the guidelines for decision making.
Risk : Hardening interest rates globally The interest expenses during the year 2006 was higher due to the global hardening of interest rates and increased borrowings by your Company to finance expansions as well as the new business initiatives. Response : Your Company has taken steps to mitigate the effects by an optimum mix of fixed / floating rate borrowings and hedge instruments wherever possible.
Political Risks :
Risk: Instability and potential closure of business Due to the changing market dynamics, operating units sometimes become unviable. Response : Your Company closely and continuously monitors the situation in every location. Whenever a location become unviable, the assets at that location is recalled / relocated as the situation demands. e.g. Nepal and Venezuela.
Financial Risks :
Risk: Foreign Exchange Fluctuation Due to the global scale of operations of Company, it is exposed to multiple currencies. The Companys performance and future could be affected by fluctuations in exchange rates. Since a major portion of our transactions are either Dollardenominated or based on Dollar prices, our exposure to a devaluation of the currencies of the countries in which we operate is limited to a significant extent. Response: Appropriate coverage clauses have been woven into the contracts with the buyers to offset the impact of currency fluctuations. Further, with the help of non-speculative
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Your Companys Revenues have increased by 23.4%, and PAT has increased by 9.2% over the previous year. Operating profits (EBIDT) have increased by 14% during 2006. Regionwise Performance
Revenue 2005
AMESA 35%
The highlights of your Companys business in each of these regions are as under : Americas The Operating Units in this region include Tube business and Medical Devices business.
Europe
18%
Americas 22%
EAP
24%
Tube business :
Revenue 2006
Americas 29%
Europe
18%
The capacities in the USA plant have been enhanced to meet the requirements of the new customers who have been tapped. The volumes are expected to grow faster in the US market as the necessary capacities are in place. The US market holds great promise for the Company. During the year 2006 your Company has started manufacturing operations of extruded plastic tubes in USA. This is our third manufacturing unit for extruded plastic tubes apart from Arista, UK, and Wada, India. Mexican operations are on turnaround path, firmly supported by a contract from a MNC Company. The volumes from Colombian operations have increased substantially. The Venezuelan capacities are in the process of being relocated to other units in the Region.
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Essel Propack UK Ltd. (erstwhile Telcon Packaging Ltd.) has improved its capacity utilization and manufacturing efficiencies during 2006. This unit is one of the focused manufacturers of laminated tubes in UK. To further consolidate our presence in Europe, Arista Tubes Ltd. is currently being restructured to align its vision with the Companys vision to consolidate and grow as a major global player in extruded plastic tubes. At the two UK subsidiaries, the emphasis is on improvement of efficiencies, cost reduction, expansion of customer base and targeting new major customer accounts. The Company expects a positive impact on its profitability during the current year. In Germany, the laminated tube volumes have improved substantially during the year. The new laminated tubes plant near Moscow, in Russia, is also going through a stabilisation phase. Plans are on to increase capacity utilization, since the market is very large and promising. Africa, Middle-East and South Asia (AMESA) The Operating Units in this region include Tube business and Specialty Packaging Materials.
The capacities of Guangzhou Propack Limited, China, (GPC) have been relocated during the year to other EP sites, following the completion of a MNC customer contract. China has posted a consistent performance during the year. The key factor which has enhanced the performance is the continuation
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Human Capital
All through the years, your Company has remained a progressive organisation, continuously monitoring and anticipating the changing market trends and evolving market dynamics. This aspect has kept your Company at the forefront of competition, always leading the change in its industry, to be termed as industry benchmark. Human capital of the Company has always remained the constant appreciating asset, which has propelled the Company to its present global status. Today, your Company has three revenue streams namely Laminated Tubes / Extruded Plastic Tubes, Medical Devices and Specialty Packaging Materials. The Company aims to post a consistent and healthy growth in all the three revenue streams simultaneously. With such a vision, the need was felt to realign the organisational goals and aspirations, to instill multi-dimensional organisational growth. To realign and transform the organisation, it was felt imperative to align the aspirations, goals, structure, capabilities, processes and people with the organisation. It was decided to undertake an indepth Diagnostic and Climate study of the organisation, the results of which, in turn, would form the frame of reference for all the changes. The services of an international respected specialist was availed to facilitate these efforts. The entire exercise was to be followed by development of Human Capital strategy and various Human Capital initiatives for implementation across the organisation. The realignment efforts were rolled out with the diagnosis of internal organisational environment vis--vis external environment such as market realities and expectations. Various critical factors such as business challenges (current and future with implications), future focused business imperatives, assessment / implication of organisation structure, diagnostic of organisation culture & climate and their implications, cultural sensitivity, criticality of top teams and their impact on the Company, detailed roadmap on implementing the recommendations in a phased manner etc. were considered and studied. The findings of this exercise formed the base for identifying the path forward. To arrive at the path for achieving the organisational goals, a Strategy
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Cautionary Statement
Statements in this Report describing the Companys objectives, expectations or predictions may be forward looking within the meaning of applicable laws and regulations. The actual results may differ materially from those expressed in this statement.
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