Vaibhav Plasto Printing & Packaging Private Limited is entering a new phase of growth with the commissioning of its expansive manufacturing facility in Nagpur. In an interview with Packaging South Asia, director Vaibhav Agrawal outlines how the new plant, technology upgrades and sustainability-led strategies position the company for scale, efficiency and long-term competitiveness.
A new plant designed for scale and efficiency
The company’s new manufacturing campus at Butibori MIDC, Nagpur, spans 15 acres, anchored by a 300,000 square feet production shed. Its central location gives the unit strong national connectivity and a clear logistics advantage. With an installed capacity of 4,000 MT a month across printing, lamination, slitting, pouching and multilayer blown film operations, the plant has been conceived as a future-ready manufacturing ecosystem.
With advanced technology, automation, and a strong focus on sustainability, this expansion strengthens our vision to stay ahead in the rapidly evolving packaging industry.
“From a humble start to becoming one of Central India’s largest flexible packaging companies, this journey has been possible only because of the trust of our customers, partners, employees, and community,” he says.
Agrawal says the expansion supports Vaibhav Plasto’s long-term strategy of strengthening customer service, reducing lead times, enhancing supply capability and deepening its national footprint.
All core production lines—high-speed gravure printing, solventless and solvent-based lamination, multilayer blown film lines with auto-thickness control, multiple slitters and pouching equipment—are integrated within the new layout.
Streamlined material flow, higher automation, energy-efficient machinery and upgraded safety systems have together reduced changeover times and improved batch consistency and overall operational efficiency.
The company has a target to achieve turnover of Rs 1,000 crore by 2030.
Why Bobst: automation, precision and continuity
The company recently invested in the latest Bobst systems, a decision shaped by the brand’s global leadership in precision engineering, process control and automation. Bobst’s installations at the plant span nearly a decade, beginning with the RS 5002, commissioned in 2016. This was followed by the NOVA RS 5003 series, reflecting the company’s steady expansion and technology upgrades.
A NOVA RS 5003 was added in 2021, and two more units of the same model were installed in 2024, marking a significant strengthening of the plant’s solvent-based lamination capacity. Together, these machines underline the converter’s long-term partnership with Bobst and its focus on modern, high-efficiency laminating solutions.
Agrawal notes that Vaibhav Plasto’s earlier experience with Bobst equipment created a strong foundation—its operators were already trained on similar platforms, allowing the new lines to achieve stable output and optimization from day one.
The new Bobst lines bring sharper registration, improved dot reproduction, tighter color consistency, and versatility across substrates. Automated tension control and inline monitoring have lowered wastage and enhanced repeatability. After evaluating multiple global suppliers, Agrawal says Bobst stood out for its depth of automation, long-term service support, energy efficiency and proven performance.
These investments now enable faster turnaround, consistent print quality and stable output—attributes increasingly demanded by FMCG and premium consumer brands.
Complementary equipment and digital workflows
Beyond the Bobst installations, the plant incorporates high-speed lamination systems, slitters, multi-track pouching machines, inspection units and converting equipment to offer end-to-end packaging solutions. Gravure remains the company’s core printing strength, supported by both solvent-based and solventless lamination, allowing for a wide range of structures.
Digital workflow tools are being implemented across prepress, colur management, viscosity control, online quality checks and job traceability. The production sequence—design, cylinder preparation, printing, lamination, curing, slitting, pouching, packing and dispatch—has benefited most from reduced material handling, faster changeovers and improved color consistency after the recent upgrades.
Markets served and core applications
Vaibhav Plasto serves a broad spectrum of consumer-centric segments including food, snacks, confectionery, beverages, household essentials and industrial applications. Its customer base is anchored in FMCG and food and beverage categories, along with snack foods, spices, frozen products and other packaged consumer goods.
Expansion roadmap and sustainability commitments
As market demand strengthens, the company plans to further expand capacity and invest in advanced converting and automation technologies. Upcoming upgrades will emphasize inline inspection, deeper digital integration and enhanced converting capability.
Sustainability is a central focus area. The company is developing recyclable structures, downgauged films, eco-friendly lamination combinations and improved solvent-recovery systems to meet customer expectations and regulatory requirements. Export opportunities are also being explored alongside continued reinforcement of the domestic market.
Industry outlook: growth with challenges
Agrawal sees India’s flexible packaging industry on a strong upward trajectory, supported by rising consumption, eCommerce penetration and brand premiumization. At the same time, medium-sized converters face persistent challenges—raw material volatility, energy costs, skilled manpower shortages and growing compliance obligations.
He believes the most promising opportunities lie in recyclable solutions, advanced barrier structures, premium finishes and high-value laminates. Companies that invest in technology, automation and process stability, he says, will be best positioned to compete in this evolving landscape.
