ACG Packaging Materials has announced that its Shirwal manufacturing facility has been formally designated a global Lighthouse and admitted into the World Economic Forum’s (WEF) Global Lighthouse Network (GLN). With this recognition, ACG becomes the world’s first pharmaceutical packaging company to be included in the network. The Shirwal honour represents the company’s second Lighthouse acknowledgement, following its earlier recognition in 2023 for the Pithampur capsules manufacturing facility.
The latest designation highlights ACG’s continued focus on applying smart manufacturing practices to advance safety, sustainability and affordability in medicines on a global scale. The World Economic Forum’s Lighthouse Network identifies manufacturing sites that demonstrate leadership in the adoption of advanced technologies to deliver measurable operational and sustainability outcomes.
Commenting on the development, Karan Singh, Managing Director, ACG, said: “ACG has always believed that true leadership in the packaging sector comes from building smarter – not competing harder. Our Shirwal facility is now our second site to be recognised by the World Economic Forum’s Global Lighthouse Network, making ACG the world’s first pharmaceutical packaging company to receive this honour.”
He added: “This achievement reflects the structures and frameworks we are putting in place across the Group. All ACG business entities are converging to optimise 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 the Shirwal site, the transformation programme covers end-to-end manufacturing operations. The initiative is supported by generative AI, machine learning, deep learning, the Industrial Internet of Things (IIoT) and digital twin technologies. Operating within a highly competitive and increasingly commoditised pharmaceutical packaging market, the facility undertook a comprehensive digital transformation to enhance productivity, agility and quality, while also lowering energy consumption and associated greenhouse gas emissions and enabling a safer, more empowered workplace.
According to the company, the programme has improved day-to-day decision-making by increasing operational visibility and enabling quicker, more consistent responses to variations across critical manufacturing processes.
As a result of these initiatives, the Shirwal facility recorded a 40% reduction in lead times, a 71% reduction in defects, a 31% reduction in energy consumption, and a 34% improvement in on-time delivery in full. For customers, these outcomes translate into shorter lead times, reduced defects and more reliable delivery performance at scale.
S R Shivshankar, CEO, ACG Packaging Materials, said: “This recognition reflects the commitment of our teams at Shirwal and their ability to integrate advanced digital technologies into everyday manufacturing operations. It strengthens our focus on delivering consistent quality, productivity and sustainability for customers worldwide.”
Balajikasiram Sundararajan, Chief Digital Officer, ACG Group, stated: “Through our Build the Future programme, ACG is driving technology-led transformation across the manufacturing value chain, enabling smart manufacturing, connected products and services, and new business models. This prestigious Global Lighthouse recognition inspires us to continue scaling innovation across our businesses.”
Kiva Allgood, Head, Centre for Advanced Manufacturing and Supply Chains, World Economic Forum, said: “Competitiveness today is no longer defined by efficiency alone, but by the ability to sense, adapt and respond at speed. The Global Lighthouse Network showcases how intelligence-led operations are placing resilience and sustainability at the core of industrial performance.”
