Made in India: Flexible packaging films from Chiripal Poly Films

Chiripal Poly Films, a part of the Chiripal Group, started the flexible packaging films operations in January 2012 by installing its first production line of BOPP films with German technology in Ahmedabad.
Today, the company manufactures both BOPP and BOPET films.

Biaxially Oriented Polypropylene (BOPP) films are manufactured out of polypropylene by casting into film and further stretching it into the machine and cross directions. Chiripal offers a wide range of BOPP films in transparent, metallised, cavitated white/ pearlised, crystal clear, matt, and solid white.

Biaxially-Oriented Polyethylene Terephthalate (BOPET) films are made of polyethylene terephthalate by casting into film and further stretching it into the machine and cross directions. Chiripal offers inline coated BOPET films such as co-polyester and acrylic coated, apart from commodity-grade films.

Chiripal Group is a diversified business conglomerate incorporated in 1972. It has expanded into various industries, including textiles, petrochemicals, packaging, education, and infrastructure.

The capacity
On the flexible packaging segment, Chiripal Poly Films currently has two BOPP lines, one BOPET line, and one offline coater with a total production capacity of 1,18,000 MTPA and four metallisers with installed capacity of 35,000 MTPA.

On the rigid packaging segment, the company expanded into backward integration by installing a PET resin manufacturing unit with 2,20,000 MTPA production capacity. The state-of-the-art resin plant is capable of producing bottle, textile, and film grade resins which ensures timely supply of raw material to the BOPET film plant, and allows serving other plastic segments, such as water and carbonated drinks packaging, and textile processing.

The company has standards certifications on quality management systems and food contact packaging. It is certified by AIB, BRC rated AA, ISO 9001, ISO 14001, and OHSAS 18001.

“We have established a reputation in terms of products, quality, and services; not only in the domestic market but internationally as well. The state-of-the-art high-performance lines have enhanced our capability to fulfil customers’ needs and fosters development of new customised films for different applications and tailor-made products,” says Bijay Sahu, senior vice-president, BOPP marketing, Chiripal Poly Films.

The company has further undertaken aggressive expansion plans. It recently installed a 2.5-m offline coating line with 5,000 MTPA, and will set a new manufacturing location in Hyderabad.
The Hyderabad plant will be equipped with a 10.4-m BOPP line with a production capacity of 55,000 MTPA, which will be operational by April 2021, and one BOPET line of 8.7-m 45000 MTPA production capacity which is likely to be operational by April 2022. The capacity of the Hyderabad plant will reach 1,00,000 TPA, and will have three metallisers of 35,000 TPA.

“Considering the width of the new BOPP 10.4-m line, our intention is to orient the production to thicker micron films. In fact, the line will be capable of producing from 10 to 70-micron BOPP films. Furthermore, it will have a flame treatment facility which will allow us to guarantee retention of dyne level for longer period which would help us serve our customers efficiently,” Sahu says.

The film
Sahu says the BOPP and BOPET films are used by converters and printers for lamination, printing, labelling, and flexible packaging applications.

Sahu says when it comes to flexible films price is a determinant buying factor. It also fluctuates proportionately with the raw material value. “However, customers also consider factors such as service, quality, and punctuality as buying determinants,” he says, adding, “Our approach is not only to produce standard products, but also to strive to provide customers with customised and tailor-made solutions to their flexible packaging
needs.”

It is a comprehensive process that involves a multidisciplinary team of experts where critical aspects such as end-application, production and printing process, inks, machinery, others, are meticulously analysed. “So far, our customised-product approach has worked effectively, and with the new capacities and facilities, we would be in an even stronger position to keep improving our strategy,” he adds.

Chiripal makes food grade BOPP and BOPET films in accordance with EC and FDA regulations.

In five-layer BOPP, the company produces label grade films with varying gloss and density which impact on yield. It also produces films with very high heat seal strength (> 1000 gm/25mm). “Our hi-res metallising machines provide uniform deposition of aluminium on the film substrates and resulting uniformity in barrier properties. Optical density can be produced from 1.8 to 3.0 for metallised OPP film,” Sahu says.

The company manufactures BOPET films with excellent tensile strength which supports various industrial applications, such as hot stamping and yarn. The inline coating system produces various types of coatings for better ink anchorage and metal adhesion. “We produce high barrier and high bond metallised films,” says Sahu. “Optical density can be produced from 0.25 to 4.0.”

Best practices
Chiripal’s customer base is not only limited to the domestic market, but also overseas. It exports to more than 60 countries, including major converters and brand owners.

Sahu says at Chiripal, the company strives to maintain high-quality hygiene standards with state-of-the-art machines ensuring proper waste management, and above all, outstanding safety measures.

“We, as a company, have been able to provide our customers with customised solutions to the best extent possible, besides making standard products. It’s, however, a thorough process wherein it takes a lot of effort to understand the customer requirements in terms of the end application, the processes it would pass through, the printing inks, methods, and machineries. Once it is understood, with the help of our experts, we offer the product which would best suits the needs of our customers. So far, this strategy has worked effectively and with new capacities and facilities, we would be in even stronger position to serve our customers and provide them customisable solutions,” he explains.

For the future, Sahu says, with the addition of its new 10.4-m BOPP line and metalliser, the company will focus on specialty films and sustainability factors. “Additionally, we aim to increase our market share in India by increasing our customer base substantially,” he concludes.