Cosmo First bets big on capacity surge: INR 400-cr BOPP line

Cosmo First is scaling its manufacturing capabilities and product portfolio to meet the evolving demands of the global flexible and speciality packaging sectors. Following a robust financial performance in FY2024-25, which saw its profit after tax (PAT) more than double to INR 133-crore, the company has ramped up production on several high-tech manufacturing lines.

Scaling capacity

A cornerstone of this global expansion is the successful commissioning of a state-of-the-art BOPP film line at its Waluj facility in Aurangabad, Maharashtra, in June 2025. Involving a capital expenditure of more than INR 400-crore, the new 5-layer, 10.4-metre-wide line adds approximately 81,200 metric tonnes to the company's annual capacity, a transformative 40% increase that brings total BOPP output to 277,000 MTPA. Group CEO Pankaj Poddar noted that the investment leverages advanced technology to create one of the most cost-efficient lines in India, strategically positioned to meet the favourable domestic supply-demand gap.

Beyond physical factory floors, the company is reinforcing its global North American supply chain with the addition of a high-speed slitter rewinder to its US operations. Domestically, the expansion continues with the commissioning of a new cast polypropylene (CPP) line in March 2025, providing an annual capacity of 22,000 MT. Furthermore, the company signalled its long-term commitment to industrial scaling by conducting the Bhoomi Pujan for a brand-new facility at Auric City, Bidkin, in February 2025, which will serve as a future hub for specialised material science.

Targeting the high-growth pet food sector

Cosmo Films has disrupted the plastic packaging sector with the late 2025 launch of a specialised range of high-performance films designed for the rapidly evolving pet food industry. Drawing insights from its digital-first pet care business, Zigly, the company engineered TR-BOPP (thermal resistant) films capable of withstanding temperatures up to 185°C. This linear-tear transparent film serves as a sustainable, recyclable alternative to the conventional PET print layers traditionally used in multi-layer pet food structures.

The portfolio also introduces ultra-high barrier (UHB) metallised BOPP, a grade specifically patterned to replace aluminium foil in flexible structures. By simplifying material constructions, this grade enables global brands to reduce their carbon footprint while maintaining critical protection against oxygen and moisture for both wet and dry food categories. Other significant grade launches include the CSP Dualcoat under the Cosmo Synthetic Paper vertical and an advanced ESD PET sheet designed to strengthen electronic component packaging.

Digital transformation and ESG leadership

The company has made significant leaps in digital resilience, achieving ISO 27001:2022 certification in October 2025 to safeguard its intellectual property and enhance data security across its global plants. This is complemented by the implementation of the Snowflake AI Data Cloud, a unified data backbone that has reportedly reduced infrastructure and maintenance costs by 75% while enabling predictive maintenance models for manufacturing equipment.

Sustainability continues to anchor the operational model, with the company currently utilising more than 50% renewable power and maintaining a Grade 3 Good Rating from CareEdge Research for its ESG assessment. With approximately 95% of manufacturing waste recycled directly back into production and a clear roadmap toward 75% renewable energy usage by 2026, Cosmo First is positioned as a preferred partner for global brands prioritising supply chain transparency and verifiable sustainable development.