Surya Global Flexi Films, the packaging films arm of Surya Food & Agro, is rapidly scaling up operations at its greenfield facility in the YEIDA industrial region near Greater Noida. The state-of-the-art plant, spread over 40 acres and located just a few kilometers from the upcoming Noida International Airport, is part of the group’s ambitious foray into flexible packaging films.

Conceived in October 2020, the plant was completed in just 18 months despite major engineering challenges, including soil reinforcement for the 300-meter-long structures that house the biaxial film lines.

The facility is currently operating two high-speed biaxial lines – a 3-layer 8.7-meter-wide Bruckner BOPP line commissioned in December 2022, and a Dornier BOPET line of the same width commissioned in October 2024. Both lines are supported by Bobst metallizers and Kampf slitters. The Bruckner line runs at up to 525 meters per minute, while the Dornier polyester line achieves speeds of 650 meters per minute.

A third line – India’s first hybrid Bruckner BOPP and BOPE 5-layer line with inline coating and high-barrier capabilities – is currently in the final phase of installation. This line is also equipped with a Bobst Expert K5 metallizer featuring Alubond technology and is expected to go into operation by mid-July 2025.

Surya Global Flexi Films has already placed orders for two additional Bruckner lines. A 10.4-meter-wide 3-layer BOPP line with a Bobst Alox metallizer and coating system is expected by end-2025 for commissioning in mid-2026. A fifth line – another 10.4-meter-wide, 5-layer Bruckner system – is expected to follow in 2026. The company is also planning its sixth and seventh biaxial lines, including a thin film line and a capacitor-grade line, for the 2027–28 financial year.

The production setup includes extensive environmental and safety measures. A 6 MW rooftop solar plant is operational, and the factory layout ensures an automated material flow from input to output. Each production line is equipped with real-time monitoring systems and dedicated slitter rewinders for finished roll output.

According to Shekhar Agarwal, director of Surya Food & Agro and Surya Global Films, the group’s experience in the FMCG sector has informed its packaging strategy. Agarwal said the company uses advanced technology and automation to produce value-added films, with only 15% of the output consumed by its own FMCG business, while the majority is supplied to packaging converters in both domestic and international markets.

The facility includes a modern laboratory with advanced testing equipment to evaluate critical quality parameters including barrier properties of metallized films. The plant is staffed by seasoned industry professionals and is scaling up distribution and sales networks in line with production increases.

With a sharp focus on sustainable, high-barrier, and specialty films, Surya Global Flexi Films is positioning itself as a major supplier in the flexible packaging industry both in India and globally.