S Kumar’s offset-flexo push for flexible packaging gains momentum

“We believe the short-run flexible packaging market is undergoing a shift,” said Manish Hansoti, the driving force behind S Kumar Multiproducts. “The new standard for presses is now between 450- and 680-mm web width, with large repeat sizes, particularly suited for 12 micron film printing. While gravure still dominates this segment, accounting for nearly 95% of the market, the shift has begun. More players are now exploring offset, flexo, and digital technologies for short to medium-run jobs such as pouches, sachets, shrink sleeves, and other film-based applications.”

Hansoti noted that while wide-web flexo is gaining popularity, its high plate and cylinder costs — combined with the technical complexity of plate mounting — often leave buyers unprepared. To address this, S Kumar has pivoted toward offset-flexo hybrid technology for flexible packaging.

Recent successes include the installation of an offset/flexo hybrid press at Avon FPP in Ahmednagar, a government-funded organisation that selected Zonten via S Kumar after evaluating several vendors. Another milestone was the delivery of a nine-colour, 680-mm hybrid offset-flexo press to Sprinpak in Gurugram. This versatile press is designed for 12 micron polyester, IML, aluminum foils, sachets, pouches, labels, film printing, laminated tubes, and 350-gsm board for carton production.

S Kumar and Avon FPP are preparing to host an open house, targeting gravure users who are considering offset as an alternative for short- to medium-run jobs.

The company has also recently completed installations of intermittent offset presses at Janus International in Thane and Vikram Printers in Pune.

“The USP of our press lies in its speed and precision,” said Hansoti. “Running at 120- to 150-m/min, our full rotary offset presses use 10 servo motors per station—no gears, no shafts—just advanced electronic controls. The presses come equipped with auto inking systems, CIP3-based PPF, and automatic registration controls.”

Team S Kumar

From LED curing to digital integration, Zonten and S Kumar are pushing the boundaries of printing innovation. Another major installation is scheduled at Moldtek in Hyderabad by May 2025.

Following Labelexpo, S Kumar has recorded over 30 new installations, including 15 high-speed slitter-rewinders, 12 flatbed and intermittent die-cutters, three flexo presses, and four hybrid presses. “We rely on word-of-mouth,” Hansoti said. “Being printers ourselves, we understand the pain points and focus on building trust.”

An upcoming open house is also planned for June-July at Dinson Labels in Navi Mumbai, where a latest-generation flexo press will be showcased. This press features dual servo motors on each station and a large chilled roller specifically designed for printing on filmic substrates.

S Kumar and Zonten have also sold a nine-colour ZTR 450 press, with three servo motors on each station and 10-inch chilled rollers to Sri Lanka-based IML leader Jayasinghe Industries for their in-house label production.

Expanding beyond India, S Kumar has made inroads into the Kenyan market. In collaboration with HP Indigo Africa and Smart Printers Nairobi, the company has installed a Zonten ZMQ digital finishing machine that combines screen printing, intermittent flexo, hot foil, IML cutting, embossing, and slitting, all in a single-pass operation.

Additional digital finishing machines are en route to India, destined for Kumar Coatings in Surat and OM SAI Printers in Pune.

“We have a high repeat customer rate, and many of our machines have been running efficiently for over 20 years,” Hansoti added. “After-sales service is a top priority for us. Our team of eight service engineers brings deep technical and printing expertise, and is supported by Zonten’s training programs.”

Zonten–S Kumar also announced a new, cost-effective inspection camera system available in both 4K and 8K resolutions, priced between Rs 23 lakh and Rs 31 lakh. Live demonstrations are available at their Ahmedabad demo centre.

Aarjav Hansoti, director at S.Kumar, highlighted the growing demand for embellishments and innovative finishing features. He also emphasised that being a one-stop solution for customers’ packaging needs is becoming increasingly important to ensure consistency of print across various formats. S Kumar’s own printing division is expanding into monocartons with a demo Komori press from Switzerland, targeting the pharma and personal care sectors with short-format jobs.

The company aims to close FY26 with revenues of Rs 100 crore, up from Rs 70 crore in FY24.

“The Indian market is unique,” Hansoti concluded. “We sell everything from compact slitter-rewinders to high-end flexo and offset presses. As India’s economy continues to grow at a rapid pace, the packaging machinery sector is reaching new heights.”