Echaar: The new benchmark for high-resolution CI flexo in India

The evolution of Echaar Equipments was best summed up by the shift in visitor sentiment at the Bharat Mandapam. At Plastindia 2023, the primary question from the industry was a skeptical “Why CI flexo?”. By Plastindia 2026, that skepticism has been replaced by absolute acceptance. “The market has accepted both the technology and Echaar as a reliable domestic machine maker,” says managing director Kirti Panchal.

A key driver of Echaar’s success is its ability to handle LDPE and other stretchable films. While these substrates have traditionally been difficult to manage at high speeds, Echaar's CI flexo presses maintain perfect registration on films ranging from 20-micron LD to thin breathable hygiene films.

Panchal explains how the perspective about Echaar has shifted from introduction of the company, to companies actually coming with jobs and specifications in hand. This evolution signals a major victory for the 'Make in India' spirit in a sector long dominated by European and Swiss machinery.

The gravure migration

The long-standing “flexo vs gravure” rivalry has reached a tipping point. While gravure has traditionally been the default for high-quality Indian packaging, Panchal observes that for critical tasks like fine line work and sharp lettering, CI flexo is now proving superior.

Echaar's technological leap is best quantified by its resolution: The company has moved from standard benchmarks to delivering consistent results at 150 to 200 LPI, with advanced setups now exceeding 300 LPI. “Big brand owners no longer ask what machines a printer has; they know Echaar machines deliver the same quality as global alternatives,” Panchal notes, highlighting that MNCs like Amcor and Constantia are now seriously evaluating Indian-made hardware.

Material intelligence: Beyond PE

Utpal Pathak, senior manager of business development, highlights that the “intelligence” of the machine must match the evolution of the substrate. Every five years, a new material shift impacts the value chain, and Echaar’s current focus is navigating the complex world of BOPP, CPP, and non-wovens:

The biscuit standard: Major players like Parle-G have largely shifted to pure BOPP for its tearability and performance on high-speed lines.

High-speed confectionery: For candies and chocolates, metallised CPP is the current benchmark. Brands like Perfetti are pushing for production speeds of 1,000 pieces per minute, requiring films that can handle extreme horizontal and vertical flow.

The non-woven revolution: Approximately 80% of the shopping bag market has shifted from PE film to non-woven materials. Echaar is proactively working with ink manufacturers on additives that allow for high-quality reverse printing on BOPP for these bags without the need for primers.

Engineering the complete eco-package

Echaar’s success is rooted in its heavy-industry background, leveraging four decades of experience in sectors like wind energy and defense to build machines with high mechanical rigidity. Its Ambernath facility currently produces five to six CI flexo machines annually, with a total capacity including stack presses and solventless laminators reaching up to 20 units. Panchal confirms they are prepared to double this capacity as demand scales.

The company's range now spans three distinct segments:

Flexomaster HR 500: The flagship gearless press capable of 500-600 m/min for high-end packaging and hygiene.

Flexodelight HL 400: A versatile mid-speed press (400 m/min) that has found success in the hygiene and FMCG sectors.

Flexosmart: An entry-level CI press (300 m/min) designed for small-to-medium converters looking for high quality without excessive automation.

Building a knowledge ecosystem

“We don't want to sell a machine unless we can provide a complete eco-package,” Panchal asserts. To bridge the learning curve of CI flexo, Echaar has collaborated with Italian tech veterans like Claudio Maggio (ex-Uteco) and CT Service SRLS to integrate patented features like Easylock for 20-second sleeve changeovers. This focus on the “human element” ensures that Indian operators, who may be more familiar with gravure, can transition to flexo with minimal friction.

Technical spotlight: Echaar’s capabilities

Printing resolution: Consistently achieving 150-200 LPI; capable of exceeding 300 LPI for elite jobs.

Substrate versatility: Proven results on BOPP, CPP, 20-micron LD film, and 11 gsm breathable films.

Sustainable operations: Features auto-wash systems, ink cooling, and hot air recirculation to minimise waste and energy consumption.

New inline coating: A nine-colour model featuring an eight-colour CI downstream and a ninth unit for inline coating (flexo, gravure, or UV).

ECG: Echaar press have demonstrated good results by printing 150 LPI job using ECG, the press has qualified and have shown the path for many printers that by standardising, they can go for ECG printing.