ACG Packaging Materials announces that its Shirwal facility has been named a global Lighthouse and welcomed into the World Economic Forum’s (WEF) Lighthouse Network (GLN). This marks ACG’s second Lighthouse recognition, following its first in 2023 for the Pithampur capsules manufacturing facility. The distinction underscores ACG's leadership in leveraging smart manufacturing to make medicines safer, sustainable, and more affordable globally.
“This achievement reflects the structures and frameworks we are putting in place across the Group," says Karan Singh, Managing Director, ACG. "All ACG business entities are converging to optimize packaging so that medicines are safer, more sustainable, and more affordable. Repetition is the test of proof – in line with our ‘Make it Better’ commitment, we are replicating this Lighthouse excellence across our facilities and pioneering Sustainability Lighthouses for responsible, resilient manufacturing from India.”
At Shirwal, the transformation program spans end-to-end manufacturing operations and is enabled by generative AI, machine learning, deep learning, the Industrial Internet of Things (IIoT), and digital twin technologies. Operating in a highly competitive and increasingly commoditized pharmaceutical packaging market, the facility undertook a comprehensive digital transformation journey to boost productivity, agility, and quality, while also reducing energy consumption and associated greenhouse gas emissions, and supporting a safer, more empowered workplace.
The program has strengthened day-to-day decision-making by bringing greater visibility to operations and enabling faster, more consistent responses to variation across key manufacturing processes.
These initiatives have delivered measurable improvements, including:
- 40% reduction in lead times
- 71% reduction in defects
- 31% reduction in energy consumption
- 34% improvement in on-time delivery in full
For customers, this translates into shorter lead times, fewer defects, and more dependable delivery performance at scale.
“This recognition reflects the commitment of our teams at Shirwal and their ability to integrate advanced digital technologies into everyday manufacturing operations," says S R Shivshankar, CEO, ACG Packaging Materials. "It strengthens our focus on delivering consistent quality, productivity and sustainability for customers worldwide.”
“Competitiveness today is no longer defined by efficiency alone, but by the ability to sense, adapt, and respond at speed, says Kiva Allgood, Head, Centre for Advanced Manufacturing and Supply Chains, World Economic Forum. "The Global Lighthouse Network showcases how intelligence-led operations are placing resilience and sustainability at the core of industrial performance.”
