Ahmedabad’s Knack Packaging plans third expansion phase

Gujarat-based manufacturer of woven sacks

Alpesh Patel, director, Knack Packaging

Ahmedabad-based Knack Packaging is one of India’s biggest manufacturers and exporters of HDPE/PP woven sacks and printed BOPP laminated PP woven sacks. With its plant located in Mehsana, about an hour’s drive from Ahmedabad city, the company is embarking on its third expansion phase which is expected to be complete by Diwali this year. The first expansion was initiated in 2013 while the second one took place two years later in 2015.

“In the current expansion phase, we are focusing on strengthening our converting department so that we can produce very high-end niche products. A new building will be coming up in the plant premises, which will house a variety of converting equipment. We plan to cater to our overseas customers and high-end Indian customers with these niche and premium products,” says Alpesh Patel, director, Knack Packaging. The company will be investing about Rs 25 crore in the infrastructure, which includes the new building and various converting equipment. Once this phase is complete, the total area of Knack’s shop floor will be about 400,000 square foot. The total area of the plant is about 700,000 square foot.

Knack 3
A sample of woven sack made by
Knack Packaging

The company manufactures products like grain and pulses bags, foods and spices bags, animal food bags, fertilizers and chemical bags, cement and wall finish bags, powder and granule bags, mineral bags, detergent bags, mehndi bags and promotional shopping bags, among others. Knack’s Mehsana plant has a converting capacity of 1,500 tons per month. The bags range from 5 kg to 75 kg and the plant can produce an average of about 700,000 bags per day of various sizes.

Impressive infrastructure

The Knack Packaging plant is an impressive structure and houses a variety of machinery in the printing and converting sections. The plant houses two woven tape lines (extruders) from Lohia Group, three laminators and four rotogravure printing presses – three from Pelican and one from C Trivedi. The plant also has circular and flat woven looms, coating and lamination machines, back seam unit, gusseting machines, cutting and stitching machines, and bales pressing machines.

Knack 2 1
A Pelican rotogravure press at Knack
Packaging’s Mehsana plant

Knack Packaging has an extremely streamlined manufacturing process. PP resins are extruded into PP fibers that help in controlling the tensile strength of the fabrics. The extruded PP fibers are woven into body fabrics through the use of circular looms. The printing process is carried out using gravures reverse printing technology on BOPP films, which are then laminated on the PP woven fabrics in roll forms. The coating thickness is then calculated and delivered on the fabrics, which is cut to length as per the size of the bags defined by the clients. Then the stitching of bags happens, which are bound into bundles and sent for dispatch.

When asked what kind of equipment will be deployed in the new converting unit, Patel declined to provide details. “I do not want to comment on these details at this moment. But I can assure you these machines will be world class.”

Exports a major area

A large proportion of Knack’s business is derived from exports. Close to 35% of the company’s sales happens in the overseas markets with developed markets, especially the US being a major area of operation. The company continues to focus on exports and regularly participates in overseas exhibitions. Last year it participated in interpack for the first time.

“We regularly participate in focused exhibitions all over the world, mainly those related to food. Last year, we exhibited at interpack for the first time as we wanted to further expand our footprint in the European continent. It was a very good experience,” Patel shares.
This year, Knack will be present at Pack Expo International that will be held in Chicago in October.

Packaging South Asia — resilient, growing and impactful — daily, monthly — always responsive

The multi-channel B2B in print and digital 17-year-old platform matches the industry’s growth trajectory. The Indian, South Asian, Southeast Asian, and Middle East packaging industries are looking beyond the resilience of the past three years. They are resuming capacity expansion and diversification, with high technology and automation in new plants and projects.

As we present our 2024 publishing plan, India’s real GDP growth for the financial year ending 31 March 2024 will exceed 6%. The packaging industry growth will match the GDP growth in volume terms and surpass it by at least 3% in terms of nominal growth allowing for price inflation in energy, raw materials, consumables, and capital equipment.

The capacity for flexible film manufacturing in India increased by 45% over the past four years. With orders in place, we expect another 20% capacity addition in 2024 and 2025. Capacities in monocartons, corrugation, aseptic liquid packaging, and labels are grown similarly. As the consumption story returns over the next six months, we expect demand to return and exceed the growth trajectory of previous years. The numbers are positive for most of the economies in the region – and as shown by our analytics, our platform increasingly reaches and influences these.

For responsible and sustainable packaging, with its attendant regulations and compliances, there is significant headroom to grow in India and the region. Our coverage includes the entire packaging supply chain – from concept to shelf and to waste collection, sorting, and recycling.

We target brand owners, product managers, raw material suppliers, packaging designers and converters, and recyclers. This is a large and complex canvas – the only thing that can work is your agile thinking and innovation together with our continuous learning and persistence.

The coming year looks to be an up year in this region, and this is the right time to plan your participation and marketing communication – in our rich and highly targeted business platform with human resources on the ground. Share your thoughts and plans to inspire and mobilize our editorial and advertising teams!

For editorial info@ippgroup.in — for advertisement ads1@ippgroup.in and for subscriptions subscription@ippgroup.in

– Naresh Khanna (25 October 2023)

Subscribe Now
unnamed 1


Subscribe to our Newsletter


Please enter your comment!
Please enter your name here