Earlier this year, New-Delhi based Kanodia Technoplast Limited has completed the second phase of expansion for its new plant in Sonipat just north of Delhi. One part of the new plant is dedicated to specialty film production with the addition of a new W&H 7-layer barrier Filmex II line. The second part of the plant is for printing and converting flexible packaging materials.
Kanodia started its first CPP film line in 2014. “The whole idea behind setting up a new plant was to enhance the supply of specialized CPP films to the market. At that time as well, ours was the largest CPP production line in the country. Today with the addition of this new line, we have become the largest producer of CPP film in India in terms of volume,” says Dhruv Kanodia, director of Kanodia Technoplast.
Kanodia started its CPP film manufacturing division with a 600-tons-a-month production capacity in 2014. With time, the market demand surpassed production. “Other major suppliers of CPP films were unable to supply as per the market demand. Most of them had older CPP lines, that were not able to cater to the quantity and quality demands of the market, which is why the consumption of CPP in the country took time to increase,” adds Kanodia. The Middle East, Europe, South America, and Southeast Asia are significant consumers of CPP films.
Kanodia benefits from a demand and supply gap
“With the long-lasting demand and supply opportunity issues, we were pretty sure that the films are not being made and supplied the way the market demands. Moreover, film suppliers were not investing in new and better technology,” Kanodia believes.
Most of Kanodia’s flexible packaging exports use CPP films and failing to find a reliable supplier of quality CPP films, it invested in its first German CPP line. It also bought a metallizer parallel to the CPP line. Kanodia ensured that the metallizer was compatible with the film line. While the CPP line was 3.1 meters wide, the metallizer that Kanodia purchased from Applied Materials, Germany was 3.25 meters wide – still the largest metallizer in India.
Even though the first CPP line had a 600-tons-a-month production capacity, it took time for Kanodia to utilize the machine at full force. “This is there with every machine. Initially, we didn’t have enough orders; there were teething issues, and we were also doing many developments on the CPP line, which didn’t allow us to reuse the machine efficiently. The production also depends upon the film structure since the production of thinner films will not utilize the full 600-ton capacity.”
Kanodia’s new 7-layer CPP line from Windmöller & Hölscher
This year, at its new Sonipat plant, Kanodia installed a 7-layer 3.3 meters wide Filmex II CPP barrier film line from Windmöller & Hölscher. “Just like always, we thought about the future of CPP film production before investing in this line. That is the reason why we invested in a 7-layer line capable of producing barrier films,” says Kanodia.
Kanodia’s is the first 7-layer CPP barrier film line in India. It is also the first-of-its-kind line in the entire world. W&H used its latest technology to build this line for Kanodia and took this project up with utmost care, according to Kanodia. With this line, Kanodia has more than doubled its CPP film-making capacity. It can now produce nearly 1,400 tons of CPP films in a month. The company is using its existing metallizer for this line, as well. “The metallizer runs at nearly double the speed of the CPP line, hence it can take care of our current demand of metallized CPP film” Kanodia explains. With its existing metallizer, Kanodia produces metalized BOPP, BOPET and PE, as well. With the new line, the company plans to target the deep draw films and thermoforming film segment as well.
Kanodia installs new flexo and gravure lines at Sonipat plant
Around three years ago, Kanodia realized that with its existing capacity, it would run short of supplies to its customers in the market. Kanodia’s customer demands have been increasing, and the quantity has grown over the years. Kanodia also didn’t have enough space within its existing capacity to add more machines. Hence, it decided to commission a new plant.
The new flexible packaging converting plant of Kanodia houses a new Cerutti R98X EVO 10-color gravure printing press from Italy. It is Cerutti’s latest gravure model and the first installed in India and the 10th globally rated to run at 500 meters a minute. “
Kanodia is one of the prominent cylinder suppliers in the country supplying to nearly 50 converters across India. The company has four Daetwyler and HELL engravers, that it uses for engraving approximately 1,600 cylinders a month. Of the 1,600 cylinders, Kanodia supplies more than 1000 to various converters. Kanodia is already in talks with suppliers to purchase another engraver by the middle of next year.
At its new plant, along with the Cerutti press, Kanodia has installed a Windmöller & Hölscher Miraflex II 10-color wide-web flexo press. “Some jobs are particular to flexo and cannot be printed on gravure and vice-versa. The high-resolution image that you get on gravure can be now matched on a CI flexo with the help of special HD flexo plates to get high-quality output. In the West, the majority of flexible film printing is flexographic – the technology is also pretty well-accepted. However, brand owners and converters are still a bit reluctant in India. For high-barrier oil pouches, sanitary napkins, UHT milk pouches, and diaper packets, flexo has been widely accepted in India,” says Kanodia.
Apart from these two printing presses, Kanodia has also installed various lamination machines – turret-type laminators from Nordmeccanica – a solvent-based and a solventless.
Last year, Kanodia installed a W&H Varex II 2.6-meter wide 3-layer blown film line. “We have a long relationship with W&H. We appreciate their latest developments in technology. So far, we’ve purchased four machines from W&H. So, we have a good working relationship with them,” Kanodia concludes.