Vadodara-based Safeco Hygiene Films, a leading manufacturer of disposable hygiene films, has invested in a new Echaar Flexodelight 8-color central impression (CI) flexo press as part of its recent capacity expansion.
In an exclusive conversation with Packaging South Asia at the company’s plant in Savli GIDC near Vadodara, directors Hiren Chawra and Abhay Maheshwari discuss the company’s journey, strategic investments, and the evolving role of flexo printing in the hygiene sector.
Safeco Hygiene, a venture of the Ayodhya Group, was established in 2011 to address the shortage of locally manufactured hygiene film components. At that time, nearly all key hygiene film materials were imported, and domestic options were scarce. “We saw an opportunity in hygiene films, a sunrise sector with strong growth potential, which aligned with our expertise in polymers and plastics,” Chawra explains.
Since its inception, Safeco has focused exclusively on hygiene films, with a dedicated facility designed and customized for this purpose. The company produces a wide range of backsheet and wrapper films, including breathable and non-breathable, embossed, deep-embossed, printed, unprinted, laminated, and non-laminated. “There is no global specification in the backsheet category that we cannot meet,” Chawra says.
Safeco is currently the only hygiene film supplier qualified by all major multinational brands operating in India, including Unicharm, Kimberly-Clark, Procter & Gamble, and Johnson & Johnson. While the company mainly provides services to domestic manufacturing, it also exports to select overseas facilities of its multinational clients.
Capacity expansion and the new flexo investment
Safeco recently completed an expansion project that included the addition of an extrusion line and the new second-generation Echaar Flexodelight 8-color CI flexo press. The current installed capacity now stands at approximately 800 metric tons per month, Maheshwari says.
The decision to invest in an advanced 8-color flexo press reflects both practical considerations and future readiness. “Historically, our presses were four- and six-color configurations. As we have grown, we saw the need for higher automation, gearless technology, and enhanced print capabilities to support customer requirements and maintain flexibility,” Chawra explains.
While typical hygiene jobs rarely exceed six colors, Safeco opted for an eight-color press to provide backup stations and allow for complex or future requirements, including potential outer packaging work.
The choice of Echaar, an Indian manufacturer, followed detailed evaluations of global and regional press makers. Chawra highlights that apart from technical features, Echaar’s strong commitment to local manufacturing and engineering capabilities played a key role in the decision.
“The build quality, components, and machining are excellent. While Echaar is relatively new in this segment, their approach and focus on precision gave us confidence. As with any new manufacturer, there is a learning curve, but we see them developing strongly,” he notes.
In addition to the new Echaar, Safeco also operates two other geared CI flexo presses and a wide range of extrusion, slitting, coating, and lamination lines. The plant also has a well-equipped laboratory with a controlled environment, capable of testing water vapour transmission rate, mechanical properties, pH, hydrostatic head, surface tensio,n and laminate peel strength. The plant also houses a quality lab. The Safeco plant has a 3.217 MW ground-based solar park operational since May 2025.
The evolution of flexo in India
Reflecting on the broader trends, Chawra emphasizes the significant growth and adoption of flexo technology in India over the past decade.
“When we started in 2011, gravure dominated hygiene film printing worldwide. Even in markets like China and Korea, nearly all hygiene films were gravure-printed,” he recalls. However, Safeco decided early on to adopt flexo, convinced it offered superior advantages in terms of hygiene compliance, lower solvent use, and greater design flexibility.
“At that time, there was almost no local ecosystem for flexo in India—few trained operators, limited pre-press capabilities, and virtually no supporting supply chain. Despite initial resistance, we believed flexo was the future, especially for hygiene films,” Chawra says.
Today, improvements in plate technology, sleeve systems, and pre-press have made flexo more versatile and capable of delivering fine vignettes and detailed graphics. “India has now become a strong flexo market, especially in Gujarat, which has emerged as a hub for flexo presses,” he adds.
Chawra points out that while the initial cost barrier was high, advancements in flexo technology have improved print quality and reduced running costs, making it an attractive option even for laminated and value-added flexible packaging.
Looking ahead: digital and hybrid possibilities
When asked about the future of digital printing in flexible packaging, Chawra notes that while digital has made strides in certain segments, its current economics and scalability still limit its applicability in hygiene film production. However, he does not rule out its potential as the technology matures further.
Hybrid solutions, combining flexo and gravure stations, are also being explored for specialized applications, particularly where unique print effects or niche requirements arise.
Market evolution and quality focus
Maheshwari also reflects on changes in the hygiene segment over the last decade. He observes that while initial market entrants often compromised on quality to compete on price, most quickly realized that consistent quality is critical for long-term success, especially in baby care and fem care categories.
“In India today, regardless of brand, the core components used in diapers are generally of good quality. There has been significant localization of components except for pulp, which still largely comes from North America,” he says.
With sustained investments, a focus on technical excellence, and a clear commitment to quality, Safeco Hygiene continues to strengthen its position as a trusted partner for global and domestic hygiene brands.
