A milestone for CI Flexo manufacturing in India: Echaar unveils new press

“We are proud to be made in India,” says Echaar’s managing director Kirti Panchal in an interview with the WhatPackaging? team Echaar’s recently concluded Open House at its Ambernath manufacturing unit. 

Panchal noted that the open house was a resounding success where Echaar showcased its latest advancements and provided a platform for its partners and potential customers to explore its cutting-edge solutions. 

The second-generation Flexodelight series, showcased at the Open House, is equipped with advanced technologies that ensure consistent print quality while minimising energy usage.

Echaar’s USP is its 100% indigenous manufacturing, producing all components, including the critical CI drum, entirely in-house. This complete in-house production ensures strict quality control and delivers machines tailored to the Indian market while maintaining global standards of reliability.

Bridging the tech gap
When asked about addressing challenges like the learning curve required to operate CI Flexo printing machines, Panchal stated that Echaar is making CI Flexo printing more accessible and environmentally friendly. Echaar has collaborated with Claudio Maggio founder and ex director of Uteco) and one of the masters of flexo technology.  This partnership, combined with Echaar’s understanding of the Indian market and operator psychology, has enabled the company to design a CI flexo press with a carbon fibre doctor chamber and the ability to notch up 500 metres on a variety of substrates.

Echaar has introduced several features to simplify operations, such as local switches for operators, enhanced HMI interfaces for real-time monitoring, and automated systems for tasks like ink management and machine cleaning. These innovations have not only reduced the reliance on manual intervention but also boosted the printability quotient. Panchal says, "The Indian packaging market is dominated by PE, as a sealant supportive layer for PET/PP based laminate structures. Mono-PE is a very small and not-so-easily accepted market. Echaar ensures one can print with PET, CPP, BOPP, BOPA on flexo." The key he says is, consistent quality and conformity to the required specifications.

One of the things, Echaar has leveraged is the inputs from its existing pool of customers. Panchal says, "As you are aware there is a learning curve for CI flexo operations. But thanks to our collaboration with partners for inks, plates and other consumables we have scored better than most. We are simplifying the process." In real terms this means the press has a quick changeover time (this is due to Easylock – a patented technology of Echaar’s Italian partner, CT Service SRLS). Also there is a full auto wash system, turrets on both the unwinder and rewinder, and an automatic reel lifter.

The future outlook
Panchal shared insights into the company’s expanding portfolio. In addition to the second-generation Flexo Delight series, Echaar is currently building four more CI Flexo machines, one stack press, and two solventless lamination machines. By the end of March, Echaar aims to have a total of six CI Flexo installations, two stack presses, and two solventless lamination machines—ensuring the Made in India marches into the double-digit installation count.

Echaar’s machines are designed to handle a wide range of materials, including BOPP, PET, LDPE, CPP, and paper. Also, Panchal shared that the tech team is working on solventless lamination machines capable of handling low-micron films, further expanding its capabilities in the packaging industry.

When it comes to energy efficiency, the company has incorporated features like hot air recirculation and ink cooling systems to optimise energy consumption.The company’s machines are also compatible with toluene-free and ketone-free solvent-based inks, which are more environmentally friendly. 

Flexo trends
Echaar has observed a growing acceptance of CI Flexo printing among brands, particularly in segments like milk packaging, oil packaging, as well as hygiene products. The technology’s environmental benefits and cost efficiency have made it an attractive option for brands looking to adopt sustainable practices. Additionally, advancements in sleeve technology and high-density inks are expected to further bridge the gap between CI Flexo and gravure printing. 

Panchal says, We can see the acceptance of flexo technology among brands for the reasons of sustainability. There is an equivalent and at times better output as compared to rotogravure."

The company is also exploring new possibilities in premiumisation and special effects, such as inline holographic printing and reverse matte coating. These innovations, combined with the ability to print at high resolutions (over 200 lpi), are opening up new opportunities for brands to differentiate their products in the market.

Looking ahead, Echaar is focused on scaling up its production capacity and exploring new markets, including exports. Meanwhile Kirti Panchal and the Echaar team return to the drawing board. The group is consistently working towards boosting the deck of offerings on their CI Flexo press. This covers downgauging, replacement of materials (lower density), TD reengineering, reduction in ink coverage along with other premiumisation ideas. Panchal says, "The press is one thing, but it's the new ideas and customisations which keeps us alert and vigilant."