Pacmor unveils long-awaited upgrade model

Based in Rajkot, Pacmor traces its origins back to 2014, when Denish Rokad and his team began analysing the industry's gaps and challenges. The gap, Rokad says, was clear. “While many vendors were offering flexible packaging, few truly understood what the customer needed. Fewer still offered end-to-end packaging solutions with a customer-first mindset.” Pacmor entered the market to change that narrative.

“Everything is under one roof from cylinders, printing, lamination, and pouch making,” says Rokad, outlining the company's integrated manufacturing model. “When we set up the cylinder plant, we decided to go all in. We wanted full control, the same team making the cylinders, using them, and ensuring quality in printing and lamination. It gives us confidence.”

What sets the company apart, according to Rokad, is the structure, which represents an R&D powerhouse with backward integration and forward integration. “You could say we are integrated at both ends,” he says.

Its plant houses a modern flexo printing set-up with an eight-colour CI press, solventless lamination, high-speed slitting, and a range of pouching capabilities, including three-side seal, centre seal, and stand-up formats. The company processes nearly 1500 to 1800-tonnes of material monthly, serving clients across the food, personal care, and export segments.

On the other end of the production line, Pacmor has invested in pouch-making and finishing capabilities. With nine high-end pouching machines from Totani, Galaxy, and XL, the company produces stand-up, zipper, slider, 3D, 4D, box, wicketed, and spouted pouches. “We make up to 20-million pouches per month,” says Rokad. “All pouch types are manufactured in-house, including shaped and custom solutions.”
Pacmor also offers test cuts and mock-ups to customers, a vital service in today’s SKU-heavy, design-sensitive market. “We use multi-up cylinders to show customers the exact look of their packs. If they want design changes, we catch it before production starts.”

From Gopal to Pacmor 

Pacmor wasn’t always Pacmor. The company was born in 2014 under the name Gopal PrintPack Solutions, serving mainly Gopal Snacks. “We started with laminates for our own group,” Rokad explains, “but within two years, we had spare capacity. That’s when we began looking outside.”

What followed was steady expansion. “We grew to more than 400 plus customers across sectors., In order to better align with its strategic vision of establishing a robust global presence and adopting world-class corporate systems, structures, and quality standards, we had to change our constitution. In Feb 2025, we officially changed the name to Pacmor Flexible, and the name Gopal was already registered in Gujarat. So we saw that as a chance to build a new identity under a new name.”

Today, the business spans 20 product categories, from snacks and namkeen to tea and coffee, and exports to over 15 countries. “We’re no longer tied to one brand. We are an independent company serving diverse markets. We print everything — polyester, BOPP, PVC, paper, LDPE, MDOPE,” Rokad says. “From 5,000-metres to 500-kilometres, we handle jobs of all scales.”

This capability is only possible because of the tightly controlled ecosystem that Rokad has built. “From pre-press to pouching, everything is housed under one roof. That includes solventless and solvent-based lamination, slitting, pouching, and even blown film.”

The first machine

In an industry where most printers begin their journey with mechanical line shaft (MLS) presses and gradually upgrade, Rokad chose a different path. “I started with ELS directly,” he states, referring to electronically line-shafted rotogravure presses. “I’ve never had MLS. All five presses are ELS.”

It was a bold move for a newcomer. When asked why he made the leap instead of climbing the conventional technology ladder, Rokad’s reasoning is pragmatic: “I was setting up a new factory. Why settle for outdated technology when you know the market is only going to demand better? Good technology gives you space to grow.”

That foresight has paid off. Pacmor today runs five ELS presses from Indian manufacturers Kohli and Pelican, and the focus remains firmly on productivity, consistency, and scalability. “There’s no point in starting small only to replace everything a few years later. If you're confident in the market, go in with conviction.”

“My first machine was from Pelican. Actually, my uncle bought it. I was pushed into this business. I studied software engineering. Packaging wasn’t my plan.” That early machine became his training ground. “I learnt a lot about technology. It was my personal learning curve.” Soon after, Rokad began exploring newer technologies. “I came across Kohli and realised our philosophies matched. I encouraged them to innovate, and they did.” In 2020, Pacmor commissioned a Kohli CR911 rotogravure press. “Their target was 400-metres per minute. I asked them to aim higher.” The result was a machine that ran at 500-metres per minute, one of India's fastest at the time. “We were amazed and a bit scared,” he admits. “But we did it.”

That success gave both companies the confidence to think bigger. Rokad says, “We wanted to show the world that India could build high-speed machines to match European standards. That’s the mindset we took forward.”

Kaku Kohli, CEO of Kohli, says, "What began as a shared vision between Pacmor and the Kohli team turned into something truly special – the creation of Thea-9one8. By combining Denish's vision with Kohli's engineering expertise, we co-created a gravure press that exceeded our expectations. Thea-9one8 isn't just a new machine, it has become a benchmark in the gravure industry for performance and reliability."
One of Pacmor’s strategic differentiators is its blown film plant, Shreeja Multi Films, producing 800-tonnes of LDPE per month. “LDPE is the backbone of most flexible packaging. Its sealing properties are unmatched. So we produce it ourselves.” The facility houses four machines and all film is manufactured for internal use.

Scaling up

Today, Pacmor operates two manufacturing sites — one in Rajkot and another in Indore. “We started construction at Indore in 2020 and commercialised it by the end of 2021,” Rokad recalls. “Space-wise, Indore is nearly double the size of Rajkot, though Rajkot still has more printing machines. But Indore can accommodate up to seven machines.”

He explains the logic behind the site. “Indore is central. It’s easier to reach any part of the country from there. Rajkot, on the other hand, will gradually become an export hub.” The current combined production capacity stands at 20,000-metric tonnes of laminates annually.

The construction of the Indore facility wasn’t without setbacks. “Just as we began building, Covid hit. Oxygen was scarce across India, and we needed it for construction. We took the call to halt the work as humanity came first.” The decision delayed the project by nearly eight months, but Rokad stands by it. “Indore was new territory for me. New language, new city. But it made sense. Four reasons, I always say: geography, government support, language, and logistics.”

Despite initial scepticism from peers, he’s convinced it was the right call. “People asked me, why Indore? But today, it’s clear. Customers are more receptive when you’re nearby. If I say I’m from Rajkot, it’s too far for many. If I say Indore, I’m within reach.”

When asked how he manages both sites, Rokad says he believes in empowering his team. “I trust them. That’s the root of everything. Rajkot is the headquarters; major decisions are made in Rajkot. We have 470 people in Rajkot and 200 in Indore.” His own travel is limited. “I go to Indore once in two or three months, unless a client is visiting. But I know the team can handle it. That’s the strength of having capable people.”

The focus on pre-press

In gravure printing, pre-press quality is non-negotiable and Rokad understands this deeply. “Without a strong pre-press setup, you might get lucky with good quality once in a while, but it won’t be consistent. To get high-quality print consistently, your pre-press must be solid.”

He invested in a dedicated in-house cylinder department, complete with GMG software, Epson proofing, and end-to-end calibration systems. “We’ve standardised inks, cylinders, proofing and printing. When a customer sends artwork, everything from file handling to engraving to ink is aligned.”

This alignment wasn’t built overnight. “Before starting our cylinder unit, I used to outsource from Imagera and Electrotone. That’s where I learned everything. Das Damodaran from Farb Technologies introduced me to GMG workflows, and I absorbed it all. Now, every three to four months, we recalibrate every part of the process. We don’t leave anything to chance.”

A new venture 

One of the newer segments Pacmor is venturing into is gravure ink manufacturing, a logical extension of its end-to-end integration strategy. For over a decade, the company relied on Hi-Tech Inks, which supplied nearly 98% of its total gravure ink requirements. But in true Pacmor fashion, backward integration didn’t stop at cylinders or blown film.

Just two months ago, Pacmor began producing its own gravure inks at the Indore facility, exclusively for in-house use. “Ink is a live component in print,” says Rokad. “It interacts with substrates, cylinders, temperature, and pressure. So, owning that part of the process gives us a huge edge.”

Hi-Tech Inks, however, continues to be a vital strategic partner, especially as Pacmor transitions through hybrid setups. Karan Mahajan, from Hi-Tech, shares how its product suite is tailored for Pacmor’s demanding requirements.

“Pacmor predominantly manufactures food-grade packaging for both domestic and export markets,” Mahajan explains. “To ensure there’s zero risk of cross-contamination, we supply our flagship non-toluene, non-ketone polyurethane-based ink system, Jikelele, which is compliant with Swiss Ordinance and Nestle standards.”

These Jikelele inks work across all substrates, including polyester, BOPP, LDPE, and aluminium foil. Critically, they support high-speed printing up to 500-metres per minute, which aligns with Pacmor’s ELS-enabled press infrastructure.

Pacmor continues to ramp up its ink manufacturing operations, balancing in-house development complemented by industry-proven partnerships.

R&D and product development

One more department Rokad takes equal pride in is the new product development (NPD) department, which includes the head of R&D, the DGM, and Rokad himself. “We work together from ideation to final execution. It's a team effort. We sit around a table, share inputs, and then move step by step.”

The team has already delivered over a dozen high-performance prototypes that have impressed industry stakeholders. “Our NPD department is like the Jasprit Bumrah of our team, focused, sharp, and always delivering.” More than 15 custom prototypes, tailored for specific industries and markets, have already been commercialised.

He says recipe development is critical. “Based on the product, we adjust the film composition to get the right sealing strength, barrier properties, and finish. That flexibility is something only vertical integration can provide.”

Global presence and green energy initiative

Pacmor's products have reached global markets, reflecting the company's growing export footprint and commitment to excellence. We are proud to serve clients across a diverse range of countries, including South Africa, Ethiopia, the USA, Sri Lanka, Canada, Djibouti, UAE, Algeria, Israel, Saudi Arabia, Bahrain, Qatar, Finland, Kuwait, and several others.

In line with our commitment to environmental responsibility and long-term sustainability, Pacmor has taken significant steps toward green energy adoption. We commissioned a 0.9 MW solar power plant in 2022, followed by the successful commissioning of another 0.9 MW solar plant in 2023. These initiatives reflect our ongoing effort to reduce our carbon footprint and support the global transition toward renewable energy.




 

Denish and Ashokkumar Rokad: Pacmor’s capacity is 24,000-metric tonnes per annum

Creating and enforcing SOPs

At Pacmor, standard operating procedures (SOPs) are the result of lived experience. “Our DGM and process heads draft the SOPs. Then they bring them to me. I review every one of them. Because I’ve worked on the shopfloor, I’ve run machines, cleaned cylinders. I know what works and what doesn’t.”

SOPs are written to accommodate real-world variables. This helps Rokad enforce export-quality standards. He says there is no distinction between domestic and export customers. “We have only one standard. Quality is a must. That’s the first thing I tell every employee.”

Rokad found his answer to ensuring alignment across factories in a book, The 4 Disciplines of Execution (4DX). “I read it during the Covid lockdown. It helps us communicate management goals down to the last man on the shopfloor.”

Pacmor is certified under BRCGS. “We’re implementing Sedex in both factories. In two months, we’ll be certified. That’s essential if you want to work with multinationals like Unilever or Nestle.”

The path ahead 

With Rajkot now running at full capacity, Pacmor’s future expansion is focused on Indore. “We’ll add one printing machine in 2026 and another in 2027. Most likely, one will be an eight-colour press, and the other a lamination line, the usual combination.” These additions will push Pacmor’s capacity beyond its current 24,000-metric tonnes per annum. 

The roadmap from FY 2023–24 to 2026–27 shows a phased expansion in lamination, printing, and pouching technologies, steadily increasing plant capacity from 2,200 to 4,000-tonnes per month.
In a crowded and often commoditised industry, Rokad says, “Three things set us apart: agility, personal attention, and our willingness to go the extra mile. Many clients struggle with large vendors who can't accommodate smaller runs or customised formats. That’s where we step in.”