How Echaar crafted the flexo revolution

Echaar Equipments' facility in Ambernath marks a significant pivot for the Indian packaging industry, signalling a transition from traditional methods to a future defined by home-grown flexo technology.

Kirti Panchal, managing director of Echaar Equipments, termed this moment as emotional and professional culmination of a journey that began in 2018.

Reflecting on the feedback from the Plastindia show, Panchal noted a profound shift in the industry's mindset. "I am happy to state that people are no longer asking — why flexo?" Panchal says. "They have accepted it as a qualified technology for a variety of substrates, including laminates which were earlier thought to be purely gravure products."

The ecosystem has matured to a level where 350 LPI (lines per inch) is a daily reality. By demonstrating commercial samples that hit 150 to 200+ LPI on challenging substrates like BOPP and thin PE, Echaar has secured a seat at the bidding table with major global brand owners.

Utpal Pathak, senior manager, business development, brought a perspective to this shift, having witnessed the transformation of the Indian retail shelf firsthand. Pathak recalled a time when flexo was a niche player, limited to the small, transparent popcorn packs found in movie theatres.

"Today, this machine is a versatile one that can help either way," Pathak explains, gesturing to the variety of samples on display. "Whether it is flexible packaging in laminated pouches, surface printing on hygiene films like nappies, or even bread bags, the applications are endless."

With the factory's 48-year heritage, over 300 employees and a facility boasting 60 CNC-controlled machines, Echaar handles everything in-house.

Now, Echaar manufactures its own CI drums. "Being independent in CI drum production is a cutting-edge advantage," Panchal explained. "Accuracy and precision are of paramount importance, and our capability to produce these high-precision parts in-house is the secret behind our success."

The HR-300 on display is bound for Europe, having met the stringent CE norms. For Panchal, qualifying for CE was more than a legal hurdle; it was a lesson in human safety that he is now applying to every machine Echaar builds.

Veterans like Pathak, Subir Dutta, and Shailesh Dharamadhikari ensure the machines are operator-friendly. Pathak notesd that the transition to this level of manufacturing required rigorous training, especially for electronic systems provided by partners like Bosch Rexroth.

Looking toward 2026, Panchal expects Echaar to deliver eight-to-ten CI presses and five-to-ten stack presses next year, targeting a 40% increase in export sales. As Ambernath emerges as a new hub for packaging excellence, the location becomes a symbol of Indian manufacturing's logistical strength.

As the open house concluded, the sentiment was one of cautious triumph. Echaar has transformed from a company that makes parts for others into a brand that defines the standard for Indian printing.