Project report for Flexible packaging / Plastic packaging manufacturing

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 Flexible packaging is the most economical method to package and is in high demand in many sectors as it preserves and distributes food, beverages, other consumables, pharmaceuticals, and other products that need extended shelf life. Multiple benefits like lightweight, small size, less power, easily disposable, and a low-carbon footprint on the environment compared to the rigid plastics, have triggered the shift. Studies have proved that flexible packaging requires much less energy at the stage of manufacturing, transportation, and disposal. One truckload of empty flat pouches is equivalent to more than 75 truckloads of empty rigid containers. The requirement of investments, lack of bank credit facilities, and a long gestation period have been impeding the adoption of newer technologies. 

Either way, the flexible packaging has helped to enhance to carry the ability of products and increases their shelf life. In the future, it will further strengthen the entire Packaging Industry and will attract more foreign companies to invest. Global key players have recognized the potential and demand in the flexible packaging market and therefore, started to expand to India. Initiatives by the Indian Government like “Make in India” are opportunities for foreign players to export, import, and provide the latest technology and innovation. Moreover, by setting up packaging institutes and collaborating with foreign universities, the Government is continuously improving the process of training potential workforce and tries to meet the need for a skilled workforce throughout.

Product / Services & process

Flexible packaging production is the product of the firm. Flexible packaging is any package or any part of a package whose shape can be readily changed. The basic processes used to manufacture flexible packaging products, including rotogravure printing, flexographic printing, adhesive lamination, extrusion lamination/coating; and finishing/slitting. These processes are then related to the machines used to practice them, emphasizing the basics of machines’ control systems, and options to minimize wasted time and materials between production jobs. Raw materials are also considered, including Paper, Foils, Polyester Film, printing Ink & adhesive. Guidance is provided on both material selection, and on adding value through enhancement or modification of the materials’ physical features.

Plant & Machinery / Equipments

Rotogravure (roto or gravure for short) is a type of intaglio printing process, which involves engraving the image onto an image carrier. In gravure printing, the image is engraved onto a cylinder because, like offset printing and flexography, it uses a rotary printing press

Lamination Machine - Several different technologies are available that cover a wide variety of applications in the food and non-food packaging industries. Web lamination is used to improve the barrier properties of the packaging material to protect the packaged item and increase its shelf life

Slitting Machine -Roll slitting is a technique heavily used by converters (industry). The converter industry normally refers to companies that print, coat, and laminate materials. A typical converter is a company that produces flexible packaging material for packaging food

Pouch making machine - Pouch making machine for sealing and cutting of pouch in various sizes

Market potential & Strategy

The Indian Packaging market was valued at 231,542.5 million units in 2017 and is estimated to grow at a CAGR of 9.2% to reach 359,421.9 million units in 2021. Flexible Packaging is the largest packaging type accounting for 159,337.4 million units in 2016, while Rigid Metal is estimated to witness the fastest CAGR of 11.5% during 2016-2021. Strong favorable demographic factors such as increasing disposable income levels, rising consumer awareness, and demand for packaged food are expected to drive the growth of the packaging industry in India. Today the key determinants of the packing industry are the shifting consumer trends, lightweight, varied package sizes, barrier properties, the shelf life of the packaged product, ease of recycling, and transport cost. 

In the whole segment, around 45% of the total production of the packaging material goes to Food & Beverages industry. The industry continues to grow rapidly, driven primarily by pharmaceuticals, foods, and beverages and provides opportunities for Wisconsin companies. The rise of the Indian middle class, the growth of organized retail, the rapid growth of exports, and India’s e-commerce boom are all fueling industry growth. Thus, adopting better packaging methods, materials, and machinery to ensure quality has become very important for Indian businesses.

The Indian packaging industry constitutes about 4 percent of the global packaging industry. The industry is underpenetrated and thus offers significant business opportunities, since India's per capita packaging consumption is only 10.5 kg per year, as compared to 109 kg in the U.S., 65 kg in Europe, 45 kg in China, and 32 kg in Brazil. Manufacturers of packaging machinery and materials in India find demand for their products mostly in the food processing and pharmaceuticals sectors. About 45 percent of the packaging machinery and materials produced is absorbed by the food processing sector alone, 25 percent by the pharmaceuticals sector, and 10 percent each by the personal products, tea and coffee, and industrial products industries. India’s imports of packaging equipment currently stand at over $130 million a year. India’s imports of packaging equipment for food processing are mainly automated machines and systems.

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