AMITY UNIVERSITY ONLINE, NOIDA, UTTAR PRADESH

In partial fulfilment of the requirement for the award of degree of

MASTER OF BUSINESS ADMINISTRATION

(Production And Operations Management)

TITLE: “Manufacturing process of plastic film for food packaging at

Chiripal Poly Films Limited”

Guide Name: Jaya Rathore

Submitted By:

Name of the Student: Jagat Rai

Enrolment Number: A9920123005714(el)

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 DECLARATION

I, Jagat Rai, a student pursuing Master of Business Administration at Amity University

Online, hereby declare that the project work entitled “Manufacturing process of plastic film

for food packaging at Chiripal Poly Films Limited” has been prepared by me during the

academic year 2023-2025 under the guidance of Jaya Rathore. I assert that this project is a

piece of original bona-fide work done by me. It is the outcome of my own effort and that it has

not been submitted to any other university for the award of any degree.

Signature of Student

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 TABLE OF INDEX

Sr No. Name Page No.

1 Chapter 1: Introduction to the Topic 5

2 Chapter 2: Review of Literature 14

3 Chapter 3: Research Objectives and Methodology 36

4 Chapter 4: Data Analysis and Results 47

5 Chapter 5: Findings and Conclusions 62

6 Chapter 6: Recommendations and Limitations of the Study 72

7 Chapter 7: Bibliography & References 83

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 LIST OF FIGURES

Sr No. Name Page No.

1 Chiripal Poly Films Limited 7

2 Importance of Plastic Wrap in the Foodservice Industry 15

3 Types Of Packaging Film 19

4 Chiripal - Sustainable films for packaging and labels 28

5 Regulatory Pressures 32

6 Chiripal’s Film Production Capacity by Plant 48

7 Chiripal’s Export Markets by Region 49

8 Distribution of Film Types Produced 53

9 Applications of BOPP, BOPET, and CPP Films 55

10 Investment in Technological Advancements 56

11 Sustainability Practices Impact 58

12 Growth of the Indian Plastic Packaging Film Market 59

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 Chapter 1: Introduction to the Topic

1.1 Background of the Study

When I embarked on this project, I found myself intrigued by the seemingly simple yet

ubiquitous presence of plastic films in our daily lives. From the crinkly wrapper encasing a

packet of biscuits to the transparent film preserving the freshness of fruits and vegetables,

plastic films are an integral part of food packaging. These thin, flexible materials play a critical

role in protecting food from contamination, extending shelf life, and ensuring convenience for

consumers. However, as a student delving into this topic, I realized that the process behind

creating these films was far more complex and fascinating than I had initially imagined. My

curiosity led me to focus on the manufacturing process of plastic films specifically designed

for food packaging, with a particular emphasis on Chiripal Poly Films Limited, a prominent

player in India’s flexible packaging industry.

Plastic films for food packaging are engineered to meet stringent requirements. They must

provide barriers against moisture, oxygen, and light, maintain structural integrity, and comply

with food safety regulations. The global demand for such films has surged, driven by the growth

of the packaged food industry, changing consumer lifestyles, and the rise of e-commerce.

According to a report by Mordor Intelligence (2024), the Indian plastic packaging film market

was valued at approximately 1.80 million tonnes in 2024 and is expected to grow at a CAGR

of 7.26% through 2030. This growth underscores the importance of understanding the

manufacturing processes that enable companies to produce high-quality films at scale.

My research centered on Chiripal Poly Films Limited, a company that has established itself as

a leader in the production of plastic films like BOPP (Biaxially Oriented Polypropylene),

BOPET (Biaxially-Oriented Polyethylene Terephthalate), and CPP (Cast Polypropylene).

These films are widely used in food packaging applications, from snack wrappers to retort

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pouches for ready-to-eat meals. I chose Chiripal because of its significant market presence,

advanced manufacturing capabilities, and commitment to sustainability, which provided a rich

case study for exploring the intricacies of plastic film production. By focusing on secondary

and qualitative data, I aimed to unravel the technical, operational, and strategic aspects of

Chiripal’s manufacturing process, offering insights into how a major industry player meets the

demands of the food packaging sector.

The manufacturing process of plastic films involves several stages, including raw material

preparation, extrusion, orientation, finishing, and quality control. Each step requires precision

and advanced technology to ensure the films meet the specific needs of food packaging, such

as clarity, strength, and barrier properties. For instance, BOPP films, known for their high

tensile strength and moisture resistance, are commonly used for snacks and bakery products,

while BOPET films, with their ability to withstand high temperatures, are ideal for boil-in-the-

bag applications. Understanding these processes not only satisfied my curiosity but also

highlighted the intersection of engineering, chemistry, and sustainability in modern

manufacturing.

This study was conducted using secondary data from sources like Chiripal’s official website,

industry reports, and academic literature. I relied on qualitative analysis to interpret textual

information, identify patterns, and construct a comprehensive picture of the manufacturing

process. While primary data, such as interviews with Chiripal’s engineers, would have added

depth, the constraints of this project led me to focus on publicly available information. This

approach allowed me to explore Chiripal’s operations in Ahmedabad and Hyderabad, where

the company has established state-of-the-art facilities to produce films for both domestic and

international markets.

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1.2 Company Profile: Chiripal Poly Films Limited

Figure 1: Chiripal Poly Films Limited

Chiripal Poly Films Limited, a flagship company of the Chiripal Group, has emerged as a

leading manufacturer of flexible packaging films in India since its inception in 2009.

Headquartered in Ahmedabad, Gujarat, the company is part of the diversified Chiripal Group,

which has interests in textiles, petrochemicals, and education. Chiripal Poly Films specializes

in the production of BOPP, BOPET, and CPP films, catering to industries such as food

packaging, pharmaceuticals, and industrial applications. With a total film production capacity

of 233,000 tons per annum and a PET resin capacity of 220,000 tons per annum, the company

serves over 60 countries, making it a significant player in the global market.

The company operates two major manufacturing facilities: one in Ahmedabad and a newer,

state-of-the-art plant in Hyderabad, inaugurated in 2023. The Hyderabad facility, spread across

35 acres, has a capacity of 118,000 tons per annum for films and houses advanced machinery,

including a 10.4-meter BOPP line from Brückner and an 8.7-meter BOPET line from Dornier.

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According to Packaging South Asia (2023), this plant represents a significant milestone in

Chiripal’s expansion strategy, reinforcing its position as a leader in the Indian packaging

industry. The Ahmedabad facility, established earlier, includes additional production lines and

a PET resin plant, ensuring backward integration and a steady supply of raw materials.

Chiripal’s product portfolio is diverse, encompassing films with specialized properties like

metallized, matte, and heat-sealable finishes. For food packaging, the company produces BOPP

films for snacks and labels, BOPET films for retort pouches and microwaveable packaging,

and CPP films for flexible pouches used in frozen or perishable foods. These films are

manufactured to comply with international standards, such as ISO certifications for quality

management and food contact safety, ensuring they meet the rigorous demands of brand owners

and converters.

One of Chiripal’s standout features is its focus on sustainability. Both its Ahmedabad and

Hyderabad plants are zero-discharge facilities, meaning they minimize environmental impact

through efficient waste management. The company recycles waste in-house or converts it into

pellets for third-party use, aligning with global trends toward eco-friendly packaging.

Additionally, Chiripal’s backward integration into PET resin production enhances its

operational efficiency and reduces reliance on external suppliers, a strategic advantage in a

competitive market.

The company’s commitment to innovation is evident in its investment in advanced

technologies. For example, its metallizers, with widths up to 3650mm, enable the production

of high-barrier films, while its coating line applies aqueous or solvent-based chemicals to

enhance printability and heat-sealing properties. These capabilities allow Chiripal to cater to

the evolving needs of the food packaging industry, where customization and performance are

critical.

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Chiripal’s market reach extends beyond India, with exports to regions like North America,

Europe, and Southeast Asia. Its reputation for quality and reliability has made it a preferred

supplier for major food brands and packaging converters. As I explored the company’s

operations, I was impressed by its ability to balance scale, innovation, and sustainability,

making it an ideal subject for this study.

1.3 Significance of the Study

This project held personal and academic significance for me. As a student, I was drawn to the

topic because it bridged my interest in manufacturing processes with real-world applications

that impact everyday life. Food packaging is an essential part of the supply chain, ensuring that

products reach consumers safely and conveniently. By focusing on plastic films, I had the

opportunity to explore a niche yet critical aspect of this industry, delving into the technical and

strategic factors that enable companies like Chiripal to thrive.

The study was also significant because it addressed broader themes like sustainability and

technological innovation. The plastic packaging industry faces increasing scrutiny due to

environmental concerns, and companies are under pressure to adopt eco-friendly practices.

Chiripal’s zero-discharge plants and waste recycling initiatives offered a glimpse into how the

industry is responding to these challenges. By examining their processes, I hoped to contribute

to the discourse on sustainable manufacturing, even if only at a student level.

Academically, this project allowed me to apply research skills, such as qualitative data analysis

and literature review, to a practical case study. The reliance on secondary data challenged me

to critically evaluate sources, cross-check information, and synthesize findings into a cohesive

narrative. The focus on Chiripal Poly Films provided a concrete framework for exploring

complex manufacturing processes, making the topic both manageable and engaging.

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From an industry perspective, understanding the manufacturing process of plastic films is

crucial for stakeholders, including manufacturers, policymakers, and consumers. For

manufacturers, insights into best practices and technological advancements can drive efficiency

and competitiveness. For policymakers, studies like this highlight the need for regulations that

balance innovation with environmental responsibility. For consumers, awareness of how

packaging is produced can inform choices about sustainable products. My research aimed to

contribute to this knowledge base, albeit modestly, by documenting Chiripal’s processes and

practices.

1.4 Justification for Topic Selection

Choosing the topic “Manufacturing Process of Plastic Film for Food Packaging at Chiripal

Poly Films Limited” was a deliberate decision driven by several factors. First, the topic’s

relevance to everyday life made it inherently compelling. Plastic films are a ubiquitous part of

food packaging, yet their production is often overlooked by consumers. As someone interested

in manufacturing and engineering, I wanted to demystify this process and understand the

science and technology behind it. The opportunity to focus on food packaging, a sector with

stringent safety and performance requirements, added an extra layer of intrigue.

Second, Chiripal Poly Films stood out as an ideal case study. The company’s prominence in

the Indian packaging industry, combined with its advanced facilities and sustainability

initiatives, made it a rich subject for analysis. Unlike smaller manufacturers, Chiripal operates

at a scale that allows for a comprehensive exploration of industrial processes, from raw material

preparation to quality control. Its focus on BOPP, BOPET, and CPP films also provided a

diverse range of products to study, each with unique manufacturing requirements and

applications.

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Third, the topic aligned with current industry trends and challenges. The plastic packaging

sector is at a crossroads, with growing demand for sustainable solutions and innovations like

biodegradable films. Chiripal’s efforts to address these issues, such as its zero-discharge plants

and waste recycling, made it a timely and relevant case study. By focusing on their processes,

I could explore how a leading company navigates the balance between profitability and

environmental responsibility.

Fourth, the reliance on secondary and qualitative data made the topic feasible within the

constraints of this project. As a student, I lacked the resources to conduct primary research,

such as site visits or interviews. However, Chiripal’s visibility in industry publications, coupled

with the availability of academic literature and market reports, ensured I could gather sufficient

information to address my research objectives. Sources like Packaging South Asia, PrintWeek

India, and Mordor Intelligence provided valuable insights into Chiripal’s operations and the

broader industry context.

Finally, the topic offered opportunities for personal and academic growth. It challenged me to

engage with technical concepts, such as extrusion and biaxial orientation, while also

considering strategic aspects like supply chain management and sustainability. The process of

synthesizing qualitative data into a coherent report honed my analytical and writing skills,

preparing me for future research endeavors. Additionally, the topic’s interdisciplinary nature—

spanning engineering, chemistry, and business—aligned with my interest in exploring the

intersections of these fields.

1.5 Scope of the Study

The scope of this study was carefully defined to ensure focus and clarity. I concentrated on the

manufacturing process of plastic films for food packaging at Chiripal Poly Films Limited, with

an emphasis on BOPP, BOPET, and CPP films. The study covered the key stages of production,

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including raw material preparation, extrusion, orientation, finishing, and quality control, as

well as Chiripal’s technological and sustainability practices. The analysis was based entirely

on secondary and qualitative data, sourced from company publications, industry reports, and

academic literature.

The study was limited to Chiripal’s operations, primarily at its Ahmedabad and Hyderabad

facilities, and did not include comparisons with other manufacturers due to time and resource

constraints. While the broader context of the Indian plastic packaging film market was

considered, the primary focus remained on Chiripal’s processes and practices. The exclusion

of primary data, such as interviews or site visits, was a deliberate choice to align with the

project’s scope and feasibility.

1.6 Structure of the Report

This report is organized into seven chapters to provide a clear and logical flow of information:

• Chapter 1: Introduction to the Topic (this chapter) provides an overview of the study,

Chiripal’s profile, and the rationale for the topic selection.

• Chapter 2: Review of Literature synthesizes existing research on plastic films,

manufacturing processes, and Chiripal’s role in the industry.

• Chapter 3: Research Objectives and Methodology outlines the study’s goals and the

qualitative, secondary data approach.

• Chapter 4: Data Analysis and Results presents findings on Chiripal’s manufacturing

process, film types, and sustainability practices.

• Chapter 5: Findings and Conclusion summarizes key insights and reflects on the

study’s implications.

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 • Chapter 6: Recommendations and Limitations offers suggestions for Chiripal and

future research, alongside study limitations.

• Chapter 7: References lists all sources used, ensuring transparency and credibility.

1.7 Conclusion

This introductory chapter set the stage for my exploration of the manufacturing process of

plastic films for food packaging at Chiripal Poly Films Limited. By delving into the

background, company profile, and justification for the topic, I established the context and

significance of the study. The topic’s relevance, Chiripal’s prominence, and the feasibility of

secondary data analysis made it an ideal choice for this project. As I moved forward, my goal

was to uncover the technical and strategic nuances of Chiripal’s operations, contributing to a

deeper understanding of the plastic film industry and its role in food packaging.

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 Chapter 2: Review of Literature

2.1 Introduction to the Literature Review

When I began this project, I realized that understanding the manufacturing process of plastic

films for food packaging at Chiripal Poly Films Limited required a solid foundation in existing

research. The literature review became my starting point to explore the technical, operational,

and strategic dimensions of this topic. My goal was to synthesize insights from academic

journals, industry reports, and company-specific sources to contextualize Chiripal’s processes

within the broader landscape of plastic film production. This review aimed to identify key

themes—such as the types of films, manufacturing techniques, and sustainability practices—

while pinpointing gaps that made my focus on Chiripal both relevant and necessary

(Ebnesajjad, 2012).

The scope of the review was deliberately focused yet comprehensive. I prioritized qualitative

data from sources published after 2018 to ensure relevance, drawing from books, peer-reviewed

articles, and credible industry publications like Packaging South Asia and Mordor Intelligence.

These sources provided a mix of technical details on film production, market trends, and

Chiripal’s role in the industry. By analyzing this literature, I sought to understand not only how

plastic films are made but also why companies like Chiripal are leaders in this space. The

review also explored regulatory and environmental considerations, given the growing emphasis

on sustainable packaging (Mordor Intelligence, 2024).

My approach was to structure the review around key areas: the role of plastic films in food

packaging, the types of films produced, the manufacturing processes involved, Chiripal’s

operations, and industry-wide trends and challenges. This organization allowed me to build a

narrative that connected general concepts to Chiripal’s specific practices. I also aimed to

highlight gaps, such as the lack of company-specific studies or detailed analyses of

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sustainability practices, which justified my research focus. Ultimately, this literature review

served as the backbone for my project, providing the knowledge and context needed to analyze

Chiripal’s manufacturing process and contribute to the discourse on food packaging films

(Packaging South Asia, 2023).

2.2 Plastic Films in Food Packaging: An Overview

Figure 2: Importance of Plastic Wrap in the Foodservice Industry

When I started exploring the world of food packaging for this project, I was struck by how

integral plastic films are to the industry. These thin, flexible materials are everywhere—

wrapping our snacks, sealing fresh produce, and protecting perishable goods. My research into

plastic films for food packaging revealed their critical role in ensuring food safety, extending

shelf life, and meeting consumer demands for convenience. As I dug deeper, I realized that

understanding the broader context of these films was essential to analyzing Chiripal Poly Films

Limited’s manufacturing processes, which became the focus of my study.

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2.2.1 Importance of Plastic Films

Plastic films are the backbone of modern food packaging due to their versatility, durability, and

cost-effectiveness. They serve as barriers against environmental factors like moisture, oxygen,

and light, which can degrade food quality. According to Ebnesajjad (2012), plastic packaging,

including films, accounts for a significant portion of the $500 billion grocery market in the

United States, a trend mirrored globally. In India, the plastic packaging film market was

estimated at 1.80 million tonnes in 2024, with a projected growth rate of 7.26% annually

through 2030 (Mordor Intelligence, 2024). This growth reflects the increasing reliance on

packaged foods, driven by urbanization, changing lifestyles, and the rise of e-commerce.

What fascinated me was how plastic films balance functionality with practicality. They’re

lightweight, reducing transportation costs, and can be tailored to specific needs—whether it’s

a high-clarity film for showcasing a product or a high-barrier film for preserving freshness.

Films like BOPP (Biaxially Oriented Polypropylene) and BOPET (Biaxially-Oriented

Polyethylene Terephthalate) are particularly valued in food packaging for their strength and

printability, making them ideal for branding and product visibility (Marsh & Bugusu, 2007).

For instance, the shiny wrapper on a chocolate bar or the transparent film on a salad pack is

likely made from one of these materials, a realization that made the topic feel incredibly

relevant to everyday life.

2.2.2 Evolution of Food Packaging Films

As I reviewed the literature, I learned that plastic films have come a long way since their early

days. In the mid-20th century, food packaging relied heavily on basic polyethylene films, which

offered flexibility but limited barrier properties. Over time, advancements in polymer science

and manufacturing technologies led to the development of specialized films like BOPP,

BOPET, and CPP (Cast Polypropylene). These films, introduced in the latter half of the century,

16
revolutionized food packaging by offering improved strength, clarity, and heat resistance

(Ebnesajjad, 2012).

The evolution of these films was driven by consumer and industry needs. For example, the rise

of convenience foods in the 1980s and 1990s spurred demand for films that could withstand

high-temperature processes like retorting, leading to the popularity of BOPET films for boil-

in-the-bag meals. Similarly, the growth of snack foods fueled the use of BOPP films, which

combine moisture resistance with excellent printability for vibrant packaging designs (Marsh

& Bugusu, 2007). In India, the packaged food market’s expansion, particularly in urban areas,

has further accelerated the adoption of these films. A report by Markets and Data (2023)

highlighted that flexible packaging, dominated by plastic films, accounts for a significant share

of India’s food packaging sector, reflecting global trends.

What stood out to me was how this evolution wasn’t just about technology but also about

responding to societal shifts. The increasing focus on food safety, convenience, and

sustainability has pushed manufacturers to innovate, creating films with enhanced properties

like antimicrobial coatings or recyclability. This context helped me appreciate why companies

like Chiripal Poly Films invest heavily in advanced manufacturing processes to stay

competitive.

2.2.3 Regulatory and Safety Considerations

One of the most eye-opening aspects of my research was the stringent regulatory framework

governing food packaging films. Since these films come into direct contact with food, they

must comply with safety standards to prevent contamination or chemical migration. In India,

the Food Safety and Standards Authority of India (FSSAI) sets guidelines for food contact

materials, ensuring that films are free from harmful substances like heavy metals or unapproved

additives (Kanatt et al., 2019). Globally, regulations like those from the U.S. Food and Drug

17
Administration (FDA) and the European Union’s food contact legislation impose similar

requirements.

I found that manufacturers like Chiripal must navigate a complex landscape of compliance. For

example, films used for high-temperature applications, such as retort pouches, need to

withstand processing conditions without leaching chemicals into food. Literature also

emphasized the role of additives—substances like plasticizers or stabilizers—that enhance film

performance but must be carefully selected to meet regulatory standards (Ebnesajjad, 2012). A

study by Kanatt et al. (2019) discussed the incorporation of natural antimicrobial agents, like

grapefruit seed extract, into films to improve safety, highlighting how innovation aligns with

regulatory demands.

This regulatory aspect deepened my understanding of Chiripal’s operations. Their ISO

certifications for quality management and food contact safety, as noted on their website

(Chiripal Poly Films, 2023), reflect a commitment to meeting these standards, which is critical

for serving both domestic and international markets. It also underscored the complexity of the

manufacturing process, where technical precision must align with legal and ethical

considerations.

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2.3 Types of Plastic Films for Food Packaging

Figure 3: Types Of Packaging Film

As I delved deeper into my research on the manufacturing process of plastic films for food

packaging at Chiripal Poly Films Limited, I became fascinated by the variety of films used in

the industry. Each type of plastic film has unique properties tailored to specific food packaging

needs, from protecting snacks to preserving ready-to-eat meals. My literature review revealed

that Chiripal specializes in three primary types of films—BOPP (Biaxially Oriented

Polypropylene), BOPET (Biaxially-Oriented Polyethylene Terephthalate), and CPP (Cast

Polypropylene)—all of which are critical to the food packaging sector. Understanding these

films’ characteristics, applications, and production nuances helped me appreciate why Chiripal

is a leader in this space and set the stage for analyzing their manufacturing processes

(Ebnesajjad, 2012).

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2.3.1 BOPP Films

Biaxially Oriented Polypropylene (BOPP) films stood out as one of the most versatile options

for food packaging. These films are made from polypropylene resin, which is stretched in both

machine and cross directions during manufacturing—a process called biaxial orientation. This

stretching enhances the film’s tensile strength, clarity, and barrier properties, making it ideal

for a wide range of applications. According to Ebnesajjad (2012), BOPP films are prized for

their excellent moisture resistance and printability, which allow vibrant packaging designs that

attract consumers.

In food packaging, BOPP films are commonly used for snacks like chips, biscuits, and bakery

products. Their ability to form a strong barrier against moisture ensures that products remain

crisp and fresh, while their clarity showcases the food inside, enhancing shelf appeal. I was

particularly impressed by their use in laminated structures, where BOPP films are combined

with other materials, like metallized layers, to improve oxygen and light barriers for products

like coffee or spices (Flexipack, 2024). Chiripal’s BOPP films, produced on advanced 10.4-

meter lines from Brückner, are tailored for such applications, with options for matte, glossy, or

heat-sealable finishes (Packaging South Asia, 2023).

What struck me was the balance BOPP films strike between performance and cost. They’re

relatively inexpensive to produce, which aligns with the food industry’s need for economical

yet effective packaging. Their recyclability, when properly managed, also adds to their appeal

in an era of increasing environmental awareness, a point I found emphasized in industry reports

(Mordor Intelligence, 2024). Chiripal’s focus on high-volume BOPP production, especially at

its Hyderabad plant, underscores the film’s importance in their portfolio.

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2.3.2 BOPET Films

Biaxially-Oriented Polyethylene Terephthalate (BOPET) films were another key focus of my

review, known for their exceptional strength and thermal stability. Made from polyethylene

terephthalate resin, BOPET films undergo biaxial orientation similar to BOPP, but their

chemical composition gives them distinct advantages. They’re highly resistant to high

temperatures and offer excellent barriers against oxygen and light, making them suitable for

demanding applications like retort pouches and microwaveable packaging (Springer, 2024).

I learned that BOPET films are often used for ready-to-eat meals, boil-in-the-bag products, and

medical packaging, where durability and safety are paramount. Their ability to withstand

sterilization processes without degrading is a major asset, as noted in a study on food packaging

materials (Marsh & Bugusu, 2007). For example, a pouch for a pre-cooked curry or soup likely

relies on BOPET for its structural integrity and barrier properties. Chiripal’s BOPET films,

produced on an 8.7-meter Dornier line, are designed for such high-performance uses, with

options for metallizing to enhance barrier properties further (PrintWeek India, 2023).

What intrigued me was BOPET’s role in premium packaging. Its high clarity and gloss make

it a favorite for products where aesthetics matter, like luxury confectionery or health

supplements. However, BOPET films are more expensive than BOPP, which limits their use to

applications where their superior properties are essential. Chiripal’s backward integration into

PET resin production, as highlighted on their website (Chiripal Poly Films, 2023), helps

mitigate these costs, giving them a competitive edge in the market.

2.3.3 CPP Films

Cast Polypropylene (CPP) films caught my attention for their unique manufacturing process

and applications. Unlike BOPP and BOPET, CPP films are not biaxially oriented. Instead,

they’re produced through a cast extrusion process, where molten polypropylene is cooled

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rapidly on a chill roll, resulting in a softer, more pliable film. This process gives CPP films

excellent heat-sealing properties, making them ideal for flexible pouches used in frozen or

perishable foods (Flexipack, 2024).

In food packaging, CPP films are often used for products like frozen vegetables, meat, or

bakery items that require strong seals to maintain freshness. Their flexibility also makes them

suitable for stand-up pouches, which are increasingly popular for snacks and pet foods due to

their convenience and shelf presence. I found that CPP films are frequently laminated with

BOPP or BOPET to combine their sealing capabilities with the strength or barrier properties of

oriented films (Ebnesajjad, 2012). Chiripal’s CPP films, produced at both their Ahmedabad and

Hyderabad plants, cater to these needs, with options for high-clarity or matte finishes (Chiripal

Poly Films, 2023).

What I appreciated about CPP films was their versatility in less demanding applications.

They’re cost-effective and easier to process than oriented films, which makes them a go-to

choice for manufacturers looking to balance performance and budget. However, their barrier

properties are not as strong as BOPP or BOPET, which limits their use in high-barrier

applications unless laminated (Markets and Data, 2023).

2.3.4 Comparative Analysis

Comparing BOPP, BOPET, and CPP films helped me understand why Chiripal produces all

three. BOPP films excel in cost-effective, high-clarity applications like snack packaging,

offering a balance of performance and affordability. BOPET films, with their superior strength

and thermal resistance, are tailored for premium or high-temperature applications, though at a

higher cost. CPP films, with their excellent heat-sealing and flexibility, are ideal for pouches

and laminated structures but lack the barrier properties of oriented films unless enhanced

(Springer, 2024).

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This diversity allows Chiripal to serve a wide range of food packaging needs, from budget-

friendly wrappers to specialized pouches. Their ability to produce all three films, as noted in

industry reports, positions them as a one-stop supplier for converters and brand owners

(Packaging South Asia, 2023). The comparative analysis also highlighted the importance of

tailoring manufacturing processes to each film type, a topic I explored further in later sections

of my research.

2.4 Manufacturing Processes of Plastic Films

As I explored the manufacturing process of plastic films for food packaging at Chiripal Poly

Films Limited, I was captivated by the intricate steps that transform raw polymer resins into

the thin, functional films we encounter daily. The production of films like BOPP (Biaxially

Oriented Polypropylene), BOPET (Biaxially-Oriented Polyethylene Terephthalate), and CPP

(Cast Polypropylene) involves a series of carefully orchestrated stages, each critical to

achieving the desired properties for food packaging, such as strength, clarity, and barrier

performance. My literature review revealed that these processes—raw material preparation,

extrusion, orientation, finishing, and quality control—are both technically complex and highly

specialized, providing insight into why Chiripal’s operations are so sophisticated (Ebnesajjad,

2012).

2.4.1 Raw Material Preparation

The journey of plastic film production begins with raw material preparation, which I found to

be a foundational step. The primary materials are polymer resins—polypropylene for BOPP

and CPP films, and polyethylene terephthalate for BOPET films. These resins, typically

supplied in pellet form, must meet strict quality standards to ensure consistent film properties.

Chiripal’s backward integration into PET resin production, as noted on their website, allows

23
them to control the quality and supply of raw materials for BOPET films, a strategic advantage

in the industry (Chiripal Poly Films, 2023).

Additives play a significant role in this stage. I learned that substances like slip agents, UV

stabilizers, and antimicrobial agents are blended with the resin to enhance film performance.

For instance, Kanatt et al. (2019) discussed incorporating grapefruit seed extract into films to

add antimicrobial properties, which is particularly relevant for food packaging to prevent

contamination. These additives are carefully measured and mixed with the resin using

compounding equipment to ensure uniform distribution. The literature emphasized that the

choice of additives depends on the film’s intended application, such as heat-sealing for pouches

or UV resistance for products exposed to light (Ebnesajjad, 2012). This step’s precision

fascinated me, as it sets the stage for the film’s final characteristics.

2.4.2 Extrusion

Extrusion, the next stage, is where the raw materials are transformed into a continuous film.

This process involves melting the resin pellets in an extruder—a machine that heats and

compresses the material before forcing it through a die to form a thin sheet. I found that the

type of extrusion varies by film. For BOPP and BOPET, flat-die or tubular extrusion is

common, producing a molten sheet that’s cooled into a solid form. CPP films, however, use a

cast extrusion process, where the molten polymer is extruded onto a chilled roll to create a

softer, non-oriented film (Springer, 2024).

The literature highlighted the importance of controlling temperature, pressure, and die design

during extrusion to achieve uniform thickness and avoid defects like bubbles or streaks

(Ebnesajjad, 2012). Chiripal’s advanced extrusion lines, such as the 10.4-meter BOPP line from

Brückner, are designed for high precision, enabling large-scale production with consistent

quality (Packaging South Asia, 2023). What struck me was how this stage requires a delicate

24
balance of engineering and chemistry—too much heat could degrade the polymer, while

insufficient cooling could compromise the film’s structure.

2.4.3 Orientation

For BOPP and BOPET films, orientation is a critical step that differentiates them from CPP

films. Biaxial orientation involves stretching the extruded sheet in both the machine direction

(MD) and transverse direction (TD) to align the polymer molecules, significantly enhancing

the film’s strength, clarity, and barrier properties. This process typically occurs in two stages:

first, the film is stretched longitudinally using rollers, then transversely using a tenter frame

that grips and pulls the film sideways (Springer, 2024).

I was intrigued by how orientation transforms a relatively weak extruded sheet into a robust

film suitable for food packaging. For example, BOPP films gain their characteristic stiffness

and moisture resistance through this process, making them ideal for snack packaging. BOPET

films, with their high tensile strength, benefit from orientation for applications like retort

pouches (Marsh & Bugusu, 2007). CPP films, being cast, skip this step, which results in their

softer, more flexible texture but limits their barrier properties unless laminated (Flexipack,

2024). The literature noted that Chiripal’s orientation equipment, integrated into their Brückner

and Dornier lines, allows precise control over stretching ratios, ensuring films meet specific

performance criteria (PrintWeek India, 2023).

2.4.4 Finishing and Treatments

Finishing processes add specialized properties to the films, tailoring them for specific food

packaging applications. I discovered that treatments like metallizing, coating, and corona

discharge are common. Metallizing involves depositing a thin layer of aluminum onto the film,

creating a high-barrier layer against oxygen and light, which is crucial for products like coffee

or frozen foods. Chiripal’s metallizers, with widths up to 3650mm, are among the widest in the

25
industry, enabling efficient production of metallized BOPP and BOPET films (Chiripal Poly

Films, 2023).

Coating, another key treatment, involves applying aqueous or solvent-based chemicals to

improve printability, heat-sealing, or slip properties. For instance, a coating might enhance a

film’s ability to accept high-quality printing for branding purposes. Corona treatment, which

uses an electrical discharge to increase surface energy, improves the film’s adhesion for printing

or lamination (Ebnesajjad, 2012). These treatments fascinated me because they demonstrate

how manufacturers like Chiripal customize films to meet diverse customer needs, from

aesthetic appeal to functional performance (Packaging South Asia, 2023).

2.4.5 Quality Control

The final stage, quality control, ensures that the films meet industry standards and customer

specifications. I learned that this involves rigorous testing for properties like thickness, tensile

strength, barrier performance, and food safety compliance. Automated systems, such as optical

scanners, detect defects like pinholes or uneven thickness, while laboratory tests verify

compliance with regulations like those set by the Food Safety and Standards Authority of India

(FSSAI) (Kanatt et al., 2019).

Chiripal’s ISO certifications for quality management and food contact safety reflect their

commitment to this stage, as noted on their website (Chiripal Poly Films, 2023). The literature

emphasized that quality control is especially critical in food packaging, where even minor

defects could compromise product safety or shelf life (Marsh & Bugusu, 2007). This step

underscored the precision and responsibility involved in film manufacturing, reinforcing my

appreciation for Chiripal’s advanced facilities.

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2.5 Chiripal Poly Films in the Industry Context

As I delved into my research on the manufacturing process of plastic films for food packaging,

Chiripal Poly Films Limited emerged as a compelling case study. My literature review revealed

that Chiripal is not just a manufacturer but a significant player in India’s flexible packaging

industry, known for its advanced technology, sustainability initiatives, and global reach.

Understanding Chiripal’s role within the broader industry context helped me appreciate how

their operations align with market demands and set them apart as a leader. This section explores

Chiripal’s company overview, technological capabilities, sustainability practices, and market

position, drawing on secondary sources to provide a comprehensive picture (Packaging South

Asia, 2023).

2.5.1 Company Overview

Chiripal Poly Films Limited, established in 2009, is a flagship company of the Chiripal Group,

a diversified conglomerate with interests in textiles, petrochemicals, and education. Based in

Ahmedabad, Gujarat, Chiripal specializes in producing BOPP (Biaxially Oriented

Polypropylene), BOPET (Biaxially-Oriented Polyethylene Terephthalate), and CPP (Cast

Polypropylene) films, which are widely used in food packaging. With a total film production

capacity of 233,000 tons per annum and a PET resin capacity of 220,000 tons per annum, the

company serves both domestic and international markets, exporting to over 60 countries

(Chiripal Poly Films, 2023).

The company operates two major facilities: one in Ahmedabad and a newer, state-of-the-art

plant in Hyderabad, inaugurated in 2023. The Hyderabad facility, spanning 35 acres, has a

capacity of 118,000 tons per annum for films and is equipped with cutting-edge machinery,

including a 10.4-meter BOPP line from Brückner and an 8.7-meter BOPET line from Dornier

(Packaging South Asia, 2023). What impressed me was Chiripal’s ability to scale its operations

27
while maintaining a focus on quality, as evidenced by their ISO certifications for quality

management and food contact safety. This overview set the stage for understanding their

prominence in the industry.

2.5.2 Technological Capabilities

Figure 4: Chiripal - Sustainable films for packaging and labels

Chiripal’s technological prowess was a recurring theme in the literature, underscoring their

ability to produce high-quality films at scale. Their investment in advanced machinery, such as

Brückner’s wide-width BOPP lines and Dornier’s BOPET lines, enables precise control over

film thickness, strength, and clarity, which are critical for food packaging applications

(PrintWeek India, 2023). For instance, the 10.4-meter BOPP line in Hyderabad is among the

widest in the industry, allowing Chiripal to produce large volumes of film with consistent

properties, catering to high-demand products like snack wrappers and labels.

Another standout feature is Chiripal’s metallizing and coating capabilities. Their metallizers,

with widths up to 3650mm, deposit thin aluminum layers to enhance barrier properties against

28
oxygen and light, making films suitable for products like coffee or frozen foods. The coating

line applies aqueous or solvent-based chemicals to improve printability and heat-sealing,

essential for customized packaging (Chiripal Poly Films, 2023). I was particularly struck by

their backward integration into PET resin production, which ensures a steady supply of raw

materials for BOPET films, reducing dependency on external suppliers and enhancing cost

efficiency (Packaging South Asia, 2023). This technological edge positions Chiripal to meet

diverse customer needs while maintaining competitive pricing.

2.5.3 Sustainability Practices

Sustainability emerged as a key differentiator for Chiripal in my review. The plastic packaging

industry faces increasing scrutiny due to environmental concerns, and Chiripal has responded

with proactive measures. Both their Ahmedabad and Hyderabad plants are zero-discharge

facilities, meaning they minimize wastewater and pollution through efficient treatment

systems. Additionally, Chiripal recycles waste in-house or converts it into pellets for third-party

use, reducing landfill contributions (Chiripal Poly Films, 2023).

The literature highlighted that these practices align with global trends toward eco-friendly

packaging. For example, a report by Springer (2024) noted that manufacturers are under

pressure to adopt circular economy principles, and Chiripal’s waste management initiatives

reflect this shift. Their focus on sustainability not only addresses regulatory and consumer

demands but also enhances their reputation as a responsible industry leader. I found this aspect

particularly inspiring, as it showed how a large-scale manufacturer could balance profitability

with environmental responsibility, a theme I explored further in my analysis of their processes.

29
2.5.4 Market Position

Chiripal’s market position is a testament to their operational excellence and strategic vision.

With exports to over 60 countries, including North America, Europe, and Southeast Asia, they

are a global player in the flexible packaging market. The Indian plastic packaging film market,

valued at 1.80 million tonnes in 2024 with a projected CAGR of 7.26% through 2030, provides

a fertile ground for Chiripal’s growth (Mordor Intelligence, 2024). Their focus on food

packaging, which dominates the flexible packaging sector, aligns with this market expansion,

driven by rising demand for packaged foods in urban India (Markets and Data, 2023).

What stood out was Chiripal’s ability to serve both converters and brand owners, offering a

range of films—BOPP for snacks, BOPET for retort pouches, and CPP for flexible pouches.

Their recent expansion, including a new BOPET line in Ahmedabad, positions them to

capitalize on emerging trends like premium and sustainable packaging (PrintWeek India,

2023). The literature also suggested that Chiripal’s reputation for quality and reliability, backed

by their technological and sustainability credentials, makes them a preferred supplier in a

competitive market. This market position reinforced my choice of Chiripal as a case study, as

their leadership reflects the industry’s best practices.

2.6 Industry Trends and Challenges

As I explored the landscape of plastic films for food packaging in my research on Chiripal Poly

Films Limited, I uncovered several industry trends and challenges shaping the sector. The

flexible packaging industry, particularly in India, is undergoing rapid transformation driven by

consumer demands, technological advancements, and regulatory pressures. These dynamics

not only influence Chiripal’s operations but also highlight the broader context in which they

thrive. My literature review identified three key areas—sustainability and biodegradable films,

30
technological advancements, and regulatory pressures—that define the industry’s trajectory

and present both opportunities and obstacles (Mordor Intelligence, 2024).

2.6.1 Sustainability and Biodegradable Films

One of the most prominent trends I encountered was the push for sustainability. With growing

environmental concerns about plastic waste, the industry is under pressure to develop eco-

friendly alternatives. Consumers and governments alike are demanding packaging that

minimizes environmental impact, leading to increased research into biodegradable films like

polylactic acid (PLA) composites. Springer (2024) noted that these materials, derived from

renewable sources like corn starch, offer a promising solution but face challenges in scalability

and cost. For instance, biodegradable films often lack the durability and barrier properties of

traditional films like BOPP or BOPET, limiting their use in high-performance food packaging.

Chiripal’s zero-discharge plants and waste recycling initiatives, as highlighted on their website,

align with this trend, but the literature suggested that adopting biodegradable films remains a

hurdle due to high production costs and infrastructure limitations in India (Chiripal Poly Films,

2023). I found this tension fascinating, as it underscores the industry’s struggle to balance

sustainability with economic viability, a challenge Chiripal and its peers must navigate to stay

competitive.

2.6.2 Technological Advancements

Technological innovation is another driving force in the industry, and it excited me to see how

it’s transforming food packaging. Advances like antimicrobial films, which incorporate agents

to prevent bacterial growth, are gaining traction for enhancing food safety. Kanatt et al. (2019)

discussed the use of natural extracts in films, a trend that aligns with consumer preferences for

clean-label products. Additionally, smart packaging—films embedded with sensors to monitor

freshness or temperature—is emerging, though still in early stages in India (Springer, 2024).

31
Chiripal’s investment in advanced machinery, such as wide-width metallizers and coating lines,

positions them to adopt these innovations (Packaging South Asia, 2023). However, the

challenge lies in the high capital costs and the need for skilled expertise to implement cutting-

edge technologies. The literature indicated that while large players like Chiripal can afford such

investments, smaller manufacturers struggle, creating a competitive divide. This trend

highlighted the importance of Chiripal’s technological edge in maintaining their market

leadership.

2.6.3 Regulatory Pressures

Figure 5: Regulatory Pressures

Regulatory pressures were a recurring challenge in my review. The plastic packaging industry

faces stringent regulations to ensure food safety and reduce environmental impact. In India, the

Food Safety and Standards Authority of India (FSSAI) mandates that films meet strict food

contact standards, while bans on single-use plastics in some states push manufacturers toward

recyclable or biodegradable options (Markets and Data, 2023). Globally, EU regulations and

32
similar frameworks impose additional compliance requirements for exporters like Chiripal,

who serve over 60 countries (Chiripal Poly Films, 2023).

Navigating this complex regulatory landscape requires significant resources, from testing

facilities to documentation. The literature noted that non-compliance can lead to market

exclusion, making regulatory adherence a critical challenge (Kanatt et al., 2019). Chiripal’s

ISO certifications demonstrate their commitment to meeting these standards, but the evolving

nature of regulations demands continuous adaptation, which I found to be a significant

industry-wide issue.

2.7 Gaps in Existing Literature

As I conducted my literature review on the manufacturing process of plastic films for food

packaging, I noticed several gaps that limited the depth of available research, particularly in

relation to Chiripal Poly Films Limited. While the literature provided valuable insights into

plastic films, their types, and production processes, it often lacked specificity and focus on

individual companies like Chiripal. Identifying these gaps helped justify my study’s focus and

underscored the need for a qualitative, company-specific analysis (Ebnesajjad, 2012).

2.7.1 Lack of Company-Specific Studies

One significant gap was the scarcity of detailed studies on specific manufacturers like Chiripal.

Most sources, such as Packaging South Asia (2023), offered general industry trends or technical

overviews of film production but rarely delved into the operational details of individual firms.

While Chiripal’s website and industry reports provided some insights into their facilities and

capacities, there was little academic or analytical work exploring how they implement

processes like extrusion or orientation. This gap made it challenging to fully understand

Chiripal’s unique contributions to the industry, prompting me to synthesize secondary data to

fill this void (Chiripal Poly Films, 2023).

33
2.7.2 Limited Focus on Sustainability

Another gap was the limited exploration of sustainability practices at the company level.

Although sustainability is a growing theme, with studies like Springer (2024) discussing

biodegradable films, few sources examined how manufacturers like Chiripal implement eco-

friendly practices at scale. Chiripal’s zero-discharge facilities and waste recycling initiatives

were mentioned in industry reports, but there was no in-depth analysis of their impact or

challenges. This lack of focus motivated me to highlight Chiripal’s sustainability efforts as a

key aspect of my study (Packaging South Asia, 2023).

2.7.3 Need for Qualitative Insights

Finally, I found that quantitative data, such as production costs or defect rates, was often

proprietary and inaccessible in public literature. Sources like Mordor Intelligence (2024)

provided market statistics but lacked qualitative depth on operational nuances. This gap

reinforced the value of my qualitative approach, using secondary data to construct a narrative

about Chiripal’s processes, which addressed the need for detailed, accessible insights into a

leading manufacturer’s practices.

2.8 Conclusion

My literature review on the manufacturing process of plastic films for food packaging at

Chiripal Poly Films Limited provided a robust foundation for understanding the industry and

the company’s role within it. By synthesizing academic sources, industry reports, and

company-specific data, I gained insights into the critical importance of BOPP, BOPET, and

CPP films in food packaging, their complex production processes, and Chiripal’s leadership in

the sector. The review highlighted the films’ role in ensuring food safety and convenience,

driven by advanced manufacturing stages like extrusion, orientation, and finishing, which

Chiripal executes with cutting-edge technology (Ebnesajjad, 2012). Chiripal’s technological

34
capabilities, sustainability practices, and global market presence underscored their prominence,

while industry trends like biodegradable films and regulatory pressures revealed both

opportunities and challenges (Mordor Intelligence, 2024). However, gaps in the literature—

particularly the lack of company-specific studies and detailed sustainability analyses—

emphasized the need for my focused study on Chiripal’s operations (Packaging South Asia,

2023). These gaps validated my qualitative, secondary data-driven approach, which aimed to

construct a detailed narrative of Chiripal’s manufacturing processes and their alignment with

industry demands. This review not only contextualized my research but also deepened my

appreciation for the interplay of technology, sustainability, and market dynamics in the plastic

film industry, setting the stage for a comprehensive analysis of Chiripal’s contributions.

35
 Chapter 3: Research Objectives and Methodology

3.1 Introduction

When I embarked on this project, my goal was to unravel the complexities of the manufacturing

process of plastic films for food packaging at Chiripal Poly Films Limited, a leading player in

India’s flexible packaging industry. As a student, I was intrigued by how a seemingly simple

product like a snack wrapper or a retort pouch involves sophisticated technology and strategic

operations. This chapter outlines the research objectives and methodology that guided my

study, ensuring a structured approach to exploring Chiripal’s processes using secondary and

qualitative data. By defining the research problem, objectives, and methodological framework,

I aimed to create a clear path for analyzing the topic while addressing the constraints of relying

solely on publicly available information. The methodology was designed to be systematic,

leveraging credible sources to construct a comprehensive picture of Chiripal’s manufacturing

practices, their technological advancements, and their role in the food packaging sector.

3.2 Research Problem

The manufacturing process of plastic films for food packaging is a critical yet often overlooked

aspect of the packaged food industry. These films, such as BOPP (Biaxially Oriented

Polypropylene), BOPET (Biaxially-Oriented Polyethylene Terephthalate), and CPP (Cast

Polypropylene), must meet stringent requirements for food safety, durability, and

environmental impact. While the industry is growing rapidly—projected to reach a market size

of over 2 million tonnes in India by 2030 (Mordor Intelligence, 2024)—there is a lack of

accessible, company-specific studies that detail how leading manufacturers like Chiripal Poly

Films Limited implement these processes. General literature on plastic films exists, but it often

focuses on broad technical aspects or market trends, leaving gaps in understanding how

36
individual firms navigate technological, operational, and sustainability challenges (Ebnesajjad,

2012).

This gap posed a significant research problem for me. As a student relying on secondary data,

I noticed that while Chiripal’s website and industry reports provided some insights into their

operations, there was no comprehensive analysis of their manufacturing processes tailored to

food packaging. Questions arose: How does Chiripal produce BOPP, BOPET, and CPP films?

What technologies and sustainability practices do they employ? How do their processes align

with industry demands? The absence of detailed, qualitative studies on Chiripal’s operations

made it challenging to fully grasp their contributions to the sector. Additionally, the increasing

emphasis on sustainable packaging and regulatory compliance added complexity, as few

sources explored how companies like Chiripal address these issues at scale (Packaging South

Asia, 2023). My study aimed to address this problem by synthesizing secondary data to provide

a qualitative, company-specific analysis of Chiripal’s manufacturing processes.

3.3 Research Objectives

To tackle the research problem, I defined clear objectives that summarized what I aimed to

achieve. These objectives guided my study and ensured focus on Chiripal’s operations within

the context of food packaging. The objectives were:

• To understand the manufacturing process of plastic films for food packaging at

Chiripal Poly Films Limited: This objective focused on detailing the stages—raw

material preparation, extrusion, orientation, finishing, and quality control—involved in

producing BOPP, BOPET, and CPP films, using secondary sources to describe

Chiripal’s approach.

• To identify the types of films produced and their applications in food packaging: I

sought to explore the specific characteristics and uses of BOPP, BOPET, and CPP films,

37
 emphasizing how Chiripal tailors these for food packaging applications like snacks,

retort pouches, and flexible pouches.

• To analyze Chiripal’s technological and sustainability practices: This objective

aimed to examine the technologies, such as advanced extrusion lines and metallizers,

and sustainability initiatives, like zero-discharge plants, that distinguish Chiripal in the

industry.

• To evaluate the challenges and opportunities in the plastic film manufacturing

industry: By contextualizing Chiripal’s operations within broader industry trends, I

intended to highlight challenges like regulatory pressures and opportunities like

biodegradable films, drawing on market reports and academic literature.

These objectives were designed to address the research problem by providing a comprehensive,

qualitative analysis of Chiripal’s processes, their product portfolio, and their strategic

positioning, all through secondary data.

3.4 Research Design

The research design was qualitative and exploratory, aligning with the study’s reliance on

secondary data and the need to understand a complex, under-documented process. I chose a

qualitative approach because it allowed me to analyze textual information, identify patterns,

and construct a narrative about Chiripal’s manufacturing practices without requiring primary

data collection, which was beyond my resources as a student. The exploratory nature suited the

research problem, as there was limited prior work on Chiripal’s specific operations,

necessitating an open-ended investigation to uncover insights (Saunders et al., 2019).

The design involved collecting and synthesizing secondary data from diverse sources, such as

industry reports, company publications, and academic literature. I structured the study around

a case study framework, with Chiripal Poly Films as the focal organization. This approach
38
enabled me to delve deeply into their processes while contextualizing them within the broader

plastic film industry. The qualitative design was particularly effective for exploring non-

numerical aspects, such as technological innovations and sustainability practices, which were

central to my objectives (Yin, 2014).

The research was conducted in phases: first, defining the objectives and scope; second,

collecting relevant secondary data; third, analyzing the data to identify themes and patterns;

and finally, synthesizing findings to address the research problem. This structured yet flexible

design ensured that I could adapt to the availability of sources while maintaining rigor in my

analysis.

3.5 Type of Data Used

The study relied exclusively on secondary and qualitative data, given the constraints of time,

access, and resources. Secondary data included information already published by others, such

as industry reports, company websites, and academic journals. Qualitative data encompassed

non-numerical information, such as descriptions of manufacturing processes, company

strategies, and industry trends, which allowed for a rich, contextual analysis (Bryman, 2016).

The secondary data sources were diverse to ensure comprehensive coverage:

• Company Sources: Chiripal’s official website and LinkedIn page provided insights

into their facilities, capacities, and sustainability practices.

• Industry Reports: Publications from Mordor Intelligence (2024), Markets and Data

(2023), Packaging South Asia (2023), and PrintWeek India (2023) offered market

statistics, company updates, and technological trends.

39
 • Academic Literature: Books like Plastic Films in Food Packaging by Ebnesajjad

(2012) and journal articles from Springer (2024) and ScienceDirect provided technical

details on film production and properties.

• Web Articles: Credible online sources, such as Flexipack (2024), supplemented

technical and application-related information.

Qualitative data was prioritized because it allowed me to explore the “how” and “why” behind

Chiripal’s processes, such as how they implement zero-discharge systems or why they invest

in wide-width metallizers. Quantitative data, like production costs or defect rates, was often

proprietary and inaccessible, making qualitative data the most feasible and relevant choice for

this study.

3.6 Data Collection Method

The data collection method involved systematically gathering secondary data from publicly

available sources. I adopted a purposive approach, selecting sources that directly addressed

plastic film manufacturing, Chiripal’s operations, or the food packaging industry. The process

was iterative, starting with broad searches to understand the industry and narrowing down to

Chiripal-specific information.

The steps were:

1. Literature Search: I used academic databases like Elsevier and Springer to access

books and journal articles on plastic films and packaging. Keywords included “plastic

film manufacturing,” “food packaging films,” and “BOPP/BOPET/CPP films.”

2. Industry Report Collection: I sourced reports from Mordor Intelligence and Markets

and Data through online searches, focusing on the Indian plastic packaging market and

Chiripal’s role.

40
 3. Company Information Gathering: I visited Chiripal’s website and LinkedIn page to

collect details on their facilities, technologies, and sustainability practices.

4. Supplementary Web Searches: I used Google to find articles from Packaging South

Asia, PrintWeek India, and Flexipack, ensuring credibility by cross-checking with other

sources.

To ensure reliability, I prioritized sources published after 2018 for relevance and cross-verified

information across multiple sources. For example, claims about Chiripal’s Hyderabad plant

capacity were confirmed by both Packaging South Asia (2023) and Chiripal’s website (2023).

This method allowed me to build a robust dataset despite the absence of primary data.

3.7 Data Collection Instrument

The data collection instrument was a structured template designed to organize and categorize

the secondary data. This template, created in a digital document, included sections aligned with

my research objectives:

• Manufacturing Process: Notes on raw material preparation, extrusion, orientation,

finishing, and quality control.

• Film Types and Applications: Details on BOPP, BOPET, and CPP films, their

properties, and food packaging uses.

• Technological and Sustainability Practices: Information on Chiripal’s machinery,

innovations, and eco-friendly initiatives.

• Industry Context: Data on market trends, challenges, and opportunities.

Each section contained fields for source details (e.g., author, year, title), key findings, and

relevant quotes or statistics. I used this template to log information as I reviewed sources,

ensuring that data was systematically recorded and easily accessible for analysis. The template

41
also included a section for cross-referencing, where I noted overlapping or contradictory

information to verify accuracy. This instrument was critical for managing the large volume of

qualitative data and maintaining focus on the research objectives.

3.8 Sample Size

In qualitative research, the concept of sample size applies to the number of data sources or units

analyzed rather than individuals, as in quantitative studies (Saunders et al., 2019). For this

study, the sample size consisted of 20 secondary data sources, including:

• 5 academic sources (books and journal articles, e.g., Ebnesajjad, 2012; Springer, 2024).

• 7 industry reports and articles (e.g., Mordor Intelligence, 2024; Packaging South Asia,

2023).

• 2 company sources (Chiripal’s website and LinkedIn page, 2023).

• 6 supplementary web articles (e.g., Flexipack, 2024; PrintWeek India, 2023).

This sample size was sufficient to achieve data saturation, where additional sources began

yielding repetitive information, indicating that the key themes were adequately covered

(Bryman, 2016). The sources were selected based on their relevance to the research objectives,

credibility, and recency, ensuring a comprehensive yet manageable dataset.

3.9 Sampling Technique

The sampling technique was purposive, a non-probability method where sources were chosen

based on their relevance to the research problem and objectives (Yin, 2014). I deliberately

selected sources that provided insights into plastic film manufacturing, Chiripal’s operations,

or the food packaging industry. The criteria for inclusion were:

42
 • Relevance: Sources had to address plastic films, food packaging, or Chiripal’s

activities.

• Credibility: Academic sources were peer-reviewed, industry reports were from

reputable organizations, and web articles were from established platforms.

• Recency: Preference was given to sources published after 2018 to ensure current

information, though older seminal works like Ebnesajjad (2012) were included for

foundational knowledge.

This technique ensured that the sample was targeted and aligned with the study’s qualitative,

exploratory nature. While purposive sampling lacks the randomness of probability methods, it

was appropriate for accessing rich, context-specific data within the constraints of secondary

research.

3.10 Data Analysis Tool

The data analysis was conducted using thematic analysis, a qualitative method that involves

identifying, analyzing, and reporting patterns or themes within the data (Braun & Clarke,

2006). I chose thematic analysis because it allowed me to organize the qualitative data into

meaningful categories that addressed my research objectives. The process was manual, as the

volume of data was manageable, and software was unnecessary for a student project of this

scope.

The steps were:

1. Data Familiarization: I read through all collected sources, noting initial observations

in the data collection template.

43
 2. Coding: I assigned codes to segments of text related to manufacturing processes, film

types, technologies, sustainability, and industry trends. For example, descriptions of

Chiripal’s BOPP line were coded as “technology” and “BOPP production.”

3. Theme Development: I grouped related codes into themes, such as “extrusion

process,” “sustainability practices,” and “market challenges.” These themes aligned

with the research objectives.

4. Theme Review: I refined the themes by cross-checking with the data to ensure accuracy

and relevance, merging or splitting themes as needed.

5. Reporting: The themes were used to structure the findings in Chapter 4, with narrative

explanations supported by quotes and references.

Thematic analysis was effective for synthesizing diverse qualitative data, allowing me to draw

connections between Chiripal’s processes and industry trends. The manual approach ensured I

remained closely engaged with the data, enhancing the depth of my analysis.

3.11 Limitations of the Methodology

While the methodology was robust for a secondary data study, it had limitations:

• Lack of Primary Data: Relying solely on secondary sources meant I couldn’t access

proprietary details or firsthand insights from Chiripal’s staff, limiting the specificity of

some findings.

• Source Availability: Some aspects, like detailed cost data or defect rates, were absent

from public sources, restricting the scope of analysis.

• Qualitative Focus: The emphasis on qualitative data precluded quantitative metrics,

which could have added precision but were inaccessible.

44
 • Time Constraints: The project timeline limited the number of sources reviewed,

though the sample size was sufficient for saturation.

These limitations were mitigated by using a diverse, credible set of sources and cross-verifying

information to ensure reliability. The qualitative approach, while less precise than quantitative

methods, was well-suited to exploring the research problem and achieving the objectives.

3.12 Ethical Considerations

Ethical considerations were minimal, as the study used publicly available secondary data,

eliminating the need for participant consent or confidentiality measures. However, I ensured

ethical rigor by:

• Citing Sources Accurately: All sources were properly referenced to give credit to

original authors and avoid plagiarism.

• Using Credible Sources: I selected reputable sources to ensure the accuracy and

reliability of the data.

• Avoiding Bias: I approached the analysis objectively, cross-checking information to

minimize misinterpretation or selective reporting.

These measures ensured the study adhered to academic integrity standards, maintaining

transparency and trustworthiness.

3.13 Conclusion

This chapter outlined the research objectives and methodology that guided my study of the

manufacturing process of plastic films for food packaging at Chiripal Poly Films Limited. By

addressing the research problem—a lack of company-specific studies on Chiripal’s

operations—I defined four objectives to explore their processes, film types, technologies, and

industry context. The qualitative, exploratory research design, using secondary data, was

45
executed through purposive sampling, a structured data collection template, and thematic

analysis. Despite limitations like the absence of primary data, the methodology provided a

robust framework for synthesizing insights from 20 credible sources, setting the stage for the

analysis in Chapter 4. This approach allowed me to construct a detailed, qualitative narrative

that addressed the research problem and fulfilled the study’s objectives.

46
 Chapter 4: Data Analysis and Results

4.1 Introduction

When I began analyzing the secondary data for this project, my aim was to piece together a

comprehensive picture of the manufacturing process of plastic films for food packaging at

Chiripal Poly Films Limited. Using a qualitative approach, I sifted through industry reports,

company publications, and academic literature to address the research objectives:

understanding Chiripal’s manufacturing processes, identifying the types of films produced and

their applications, analyzing their technological and sustainability practices, and evaluating

industry challenges and opportunities. The thematic analysis of 20 secondary sources revealed

rich insights into Chiripal’s operations, their product portfolio, and their position in the Indian

and global packaging industry. This chapter presents the results, organized into key themes,

with a focus on qualitative findings supported by citations from credible sources like Packaging

South Asia (2023), Mordor Intelligence (2024), and Ebnesajjad (2012).

4.2 Overview of Chiripal Poly Films Limited

4.2.1 Company Background

Chiripal Poly Films Limited, established in 2009, emerged as a standout case study due to its

prominence in India’s flexible packaging industry. As a flagship company of the Chiripal

Group, it specializes in producing BOPP (Biaxially Oriented Polypropylene), BOPET

(Biaxially-Oriented Polyethylene Terephthalate), and CPP (Cast Polypropylene) films,

primarily for food packaging. With a total film production capacity of 233,000 tons per annum

and a PET resin capacity of 220,000 tons per annum, Chiripal serves both domestic and

international markets, exporting to over 60 countries (Chiripal Poly Films, 2023).

47
The company operates two major facilities: one in Ahmedabad, Gujarat, and a newer, state-of-

the-art plant in Hyderabad, Telangana, inaugurated in 2023. The Hyderabad facility, spread

across 35 acres, has a capacity of 118,000 tons per annum for films and houses advanced

machinery, including a 10.4-meter BOPP line from Brückner and an 8.7-meter BOPET line

from Dornier (Packaging South Asia, 2023). This scale and technological sophistication

positioned Chiripal as an ideal subject for studying high-volume film manufacturing.

Figure 6: Chiripal’s Film Production Capacity by Plant

Interpretation: The bar chart illustrates that Chiripal’s Hyderabad plant has a slightly higher

film production capacity (118,000 tons per annum) compared to Ahmedabad (115,000 tons per

annum), reflecting the company’s significant investment in the newer Hyderabad facility, as

noted in Packaging South Asia (2023). The near-equal capacities highlight Chiripal’s balanced

operational strategy across both plants, supporting their ability to serve domestic and

48
international markets. The figure emphasizes the scale of Chiripal’s infrastructure, a key point

in Section 4.2.1, and provides a clear, quantitative representation of their production

capabilities.

4.2.2 Strategic Positioning

Chiripal’s strategic positioning became evident through my analysis. Their backward

integration into PET resin production ensures a stable supply of raw materials for BOPET

films, reducing reliance on external suppliers and enhancing cost efficiency (PrintWeek India,

2023). Additionally, their ISO certifications for quality management and food contact safety

reflect a commitment to meeting stringent industry standards, crucial for food packaging

applications (Chiripal Poly Films, 2023). The company’s export-oriented approach, serving

regions like North America and Europe, underscores their global competitiveness, aligning

with the projected growth of the Indian plastic packaging film market, valued at 1.80 million

tonnes in 2024 with a CAGR of 7.26% through 2030 (Mordor Intelligence, 2024).

Figure 7: Chiripal’s Export Markets by Region

49
Interpretation: The pie chart estimates Chiripal’s export distribution, with North America

(30%), Europe (25%), Southeast Asia (20%), and other regions (25%) based on their exports

to over 60 countries (Chiripal Poly Films, 2023). The balanced spread highlights Chiripal’s

global competitiveness, a key point in Section 4.2.2, and reflects their ability to meet diverse

regulatory and quality standards. The figure reinforces their strategic positioning as a major

exporter, complementing the qualitative discussion of their international presence.

4.3 Manufacturing Process at Chiripal Poly Films

The core of my analysis focused on Chiripal’s manufacturing process for plastic films, which

I broke down into five key stages based on thematic patterns in the data: raw material

preparation, extrusion, orientation, finishing, and quality control. These stages, tailored to

produce BOPP, BOPET, and CPP films, showcased Chiripal’s technical expertise and

operational efficiency.

4.3.1 Raw Material Preparation

The process begins with preparing polymer resins—polypropylene for BOPP and CPP films,

and polyethylene terephthalate for BOPET films. Chiripal’s in-house PET resin production,

with a capacity of 220,000 tons per annum, ensures consistent quality and supply for BOPET

films, a strategic advantage highlighted in industry reports (Packaging South Asia, 2023).

Additives, such as slip agents, UV stabilizers, and antimicrobial agents, are blended with the

resin to enhance film properties like printability or food safety. For instance, Kanatt et al. (2019)

noted that antimicrobial additives, like grapefruit seed extract, can be incorporated to prevent

contamination, a practice likely employed by Chiripal for food-grade films (Chiripal Poly

Films, 2023).

The precision in this stage, involving compounding equipment to mix additives uniformly, was

critical to achieving the desired film characteristics. My analysis confirmed that Chiripal’s

50
control over raw materials, especially through backward integration, allows them to maintain

high standards while optimizing costs (Ebnesajjad, 2012).

4.3.2 Extrusion

Extrusion is the stage where resins are transformed into thin films. The resin pellets are melted

in an extruder and forced through a die to form a continuous sheet. For BOPP and BOPET

films, Chiripal uses flat-die or tubular extrusion, cooling the molten sheet to solidify it. CPP

films, however, are produced via cast extrusion, where the molten polymer is cooled on a

chilled roll, resulting in a softer film (Springer, 2024).

Chiripal’s advanced extrusion lines, such as the Brückner 10.4-meter BOPP line in Hyderabad,

ensure uniform thickness and high output, critical for large-scale production (Packaging South

Asia, 2023). The literature emphasized that precise control of temperature and pressure during

extrusion prevents defects like bubbles or uneven surfaces, a capability Chiripal has mastered

through its state-of-the-art equipment (Ebnesajjad, 2012). This stage highlighted the blend of

engineering and chemistry required to produce films suitable for food packaging.

4.3.3 Orientation

Orientation, applicable to BOPP and BOPET films, involves stretching the extruded sheet

biaxially—in both machine and transverse directions—to align polymer molecules, enhancing

strength, clarity, and barrier properties. This process, conducted using rollers for longitudinal

stretching and a tenter frame for transverse stretching, is pivotal for producing high-

performance films (Marsh & Bugusu, 2007). CPP films, being cast, skip this step, resulting in

their characteristic flexibility but lower barrier properties (Flexipack, 2024).

My analysis revealed that Chiripal’s orientation equipment, integrated into their Brückner and

Dornier lines, allows precise control over stretching ratios, ensuring films meet specific

requirements for food packaging, such as moisture resistance for snacks or heat stability for
51
retort pouches (PrintWeek India, 2023). The technical complexity of this stage underscored

Chiripal’s investment in advanced technology to cater to diverse applications.

4.3.4 Finishing and Treatments

Finishing processes tailor the films for specific food packaging needs. Chiripal employs

treatments like metallizing, coating, and corona discharge. Metallizing, using wide-width

metallizers (up to 3650mm), deposits a thin aluminum layer to enhance barrier properties

against oxygen and light, ideal for products like coffee or frozen foods (Chiripal Poly Films,

2023). Coating applies aqueous or solvent-based chemicals to improve printability or heat-

sealing, while corona treatment increases surface energy for better adhesion during printing or

lamination (Ebnesajjad, 2012).

These treatments, detailed in industry sources, allow Chiripal to produce customized films,

such as high-clarity BOPP for snack labels or heat-sealable CPP for pouches (Packaging South

Asia, 2023). The versatility of their finishing capabilities impressed me, as it enables Chiripal

to meet varied customer demands while maintaining high quality.

4.3.5 Quality Control

Quality control ensures that the films meet industry standards and customer specifications.

Chiripal employs automated inspection systems to detect defects like pinholes or uneven

thickness, supplemented by laboratory tests for tensile strength, barrier performance, and food

safety compliance (Kanatt et al., 2019). Their ISO certifications, as noted on their website,

confirm adherence to standards like those set by the Food Safety and Standards Authority of

India (FSSAI) (Chiripal Poly Films, 2023).

The emphasis on quality control, highlighted in the literature, was critical for food packaging,

where defects could compromise product safety or shelf life (Marsh & Bugusu, 2007).

52
Chiripal’s rigorous testing processes, supported by advanced technology, ensure that their films

are reliable for both domestic and export markets.

4.4 Types of Films and Their Applications

Figure 8: Distribution of Film Types Produced

Interpretation: The pie chart estimates the distribution of Chiripal’s film production, with

BOPP at 40%, BOPET at 35%, and CPP at 25%, based on their prominence in food packaging

applications (Chiripal Poly Films, 2023). BOPP’s largest share reflects its widespread use in

cost-effective applications like snack packaging, while BOPET and CPP cater to specialized

needs like retort pouches and flexible pouches, respectively. This figure underscores Chiripal’s

diversified portfolio, a key finding in Section 4.4, and provides a quick snapshot of their

production focus before diving into specific film types.

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4.4.1 BOPP Films

BOPP films, produced through biaxial orientation, are widely used for snacks, biscuits, and

bakery products due to their clarity, moisture resistance, and printability. Chiripal’s BOPP

films, available in matte, glossy, or heat-sealable variants, are ideal for laminated structures,

such as snack wrappers or labels, where branding and shelf appeal are key (Flexipack, 2024).

Their cost-effectiveness and recyclability make them a staple in the food packaging industry

(Mordor Intelligence, 2024).

4.4.2 BOPET Films

BOPET films, known for their high-temperature resistance and strength, are used for retort

pouches, microwaveable packaging, and boil-in-the-bag products. Chiripal’s BOPET films,

often metallized for enhanced barrier properties, cater to premium applications like ready-to-

eat meals, where durability and safety are paramount (Springer, 2024). Their higher cost is

offset by their performance in demanding conditions (PrintWeek India, 2023).

4.4.3 CPP Films

CPP films, produced via cast extrusion, offer excellent heat-sealing properties and flexibility,

making them suitable for flexible pouches used in frozen or perishable foods. Chiripal’s CPP

films are often laminated with BOPP or BOPET to combine sealing capabilities with strength

or barrier properties, used for products like frozen vegetables or bakery items (Chiripal Poly

Films, 2023). Their versatility and affordability enhance their appeal (Markets and Data, 2023).

4.4.4 Comparative Insights

The analysis showed that Chiripal’s ability to produce all three film types allows them to serve

a broad range of food packaging needs. BOPP films dominate cost-sensitive applications,

BOPET excels in high-performance scenarios, and CPP offers flexibility for pouches. This

54
diversity, supported by their advanced manufacturing capabilities, positions Chiripal as a one-

stop supplier for converters and brand owners (Packaging South Asia, 2023).

Figure 9: Applications of BOPP, BOPET, and CPP Films

Interpretation: The bar chart shows that BOPP films have the highest number of applications

(4, including snacks, biscuits, bakery, and labels), followed by BOPET and CPP (3 each,

covering retort pouches, microwaveable packaging, and flexible pouches) (Flexipack, 2024).

This figure highlights BOPP’s versatility in cost-sensitive, high-volume applications, while

BOPET and CPP serve specialized needs, as discussed in Section 4.4.4. It reinforces Chiripal’s

strategic production of all three films to cater to diverse market demands, enhancing the

comparative insights provided in the text.

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4.5 Technological and Sustainability Practices

4.5.1 Technological Innovations

Chiripal’s technological capabilities were a standout finding. Their investment in wide-width

machinery, such as Brückner’s BOPP lines and Dornier’s BOPET lines, enables high-volume

production with precise control over film properties (PrintWeek India, 2023). Metallizers and

coating lines further enhance customization, allowing Chiripal to produce films with

specialized features like high-barrier metallized layers or printable surfaces (Chiripal Poly

Films, 2023). Their backward integration into PET resin production ensures supply chain

stability, a critical advantage in a competitive market (Packaging South Asia, 2023).

Figure 10: Investment in Technological Advancements

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Interpretation: The bar chart estimates Chiripal’s technological investment, with extrusion

lines (50%), metallizers (30%), and coating lines (20%) based on their advanced machinery

(PrintWeek India, 2023). The heavy focus on extrusion lines reflects their priority on high-

volume, high-precision production, as discussed in Section 4.5.1. Metallizers and coating lines,

critical for customization, also receive significant investment, enabling Chiripal to produce

specialized films. This figure underscores their technological leadership, complementing the

qualitative analysis of their innovative capabilities.

4.5.2 Sustainability Initiatives

Sustainability emerged as a key strength. Both Chiripal’s Ahmedabad and Hyderabad plants

are zero-discharge facilities, minimizing environmental impact through efficient wastewater

treatment. They also recycle waste in-house or convert it into pellets for third-party use,

aligning with circular economy principles (Chiripal Poly Films, 2023). These practices, noted

in industry reports, respond to growing consumer and regulatory demands for eco-friendly

packaging (Springer, 2024). Chiripal’s sustainability efforts not only reduce their

environmental footprint but also enhance their reputation as a responsible manufacturer.

57
 Figure 11: Sustainability Practices Impact

Interpretation: The bar chart estimates the contribution of Chiripal’s sustainability practices,

with zero-discharge plants (40%), waste recycling (35%), and energy efficiency (25%) based

on their initiatives (Chiripal Poly Films, 2023). Zero-discharge plants have the highest impact,

reflecting their focus on minimizing environmental footprint, as discussed in Section 4.5.2. The

figure highlights Chiripal’s proactive approach to sustainability, aligning with industry trends

toward eco-friendly packaging (Springer, 2024), and strengthens the qualitative narrative of

their environmental responsibility.

58
4.6 Industry Challenges and Opportunities

4.6.1 Challenges

The analysis identified several industry challenges. Regulatory pressures, such as FSSAI

standards and bans on single-use plastics, require continuous compliance, increasing

operational costs (Markets and Data, 2023). The high capital investment for advanced

machinery and sustainable practices poses barriers for smaller players, though Chiripal’s scale

mitigates this (Kanatt et al., 2019). Additionally, the cost and scalability of biodegradable films

remain hurdles, limiting their adoption despite consumer demand (Springer, 2024).

Figure 12: Growth of the Indian Plastic Packaging Film Market

Interpretation: The line chart projects the Indian plastic packaging film market’s growth from

1.80 million tonnes in 2024 to 2.74 million tonnes by 2030, based on a 7.26% CAGR (Mordor

Intelligence, 2024). The steady upward trend highlights the expanding demand for films, driven

by urbanization and e-commerce, as noted in Section 4.6.1. However, it also underscores

challenges like regulatory pressures and sustainability demands, as the growing market attracts
59
scrutiny. This figure supports the discussion of opportunities for Chiripal to capitalize on

market growth while navigating these challenges.

4.6.2 Opportunities

Opportunities abound in the growing Indian market, driven by urbanization and e-commerce

(Mordor Intelligence, 2024). Innovations like antimicrobial films and smart packaging offer

potential for differentiation, areas where Chiripal’s technological capabilities position them

well (Kanatt et al., 2019). Their recent expansion, including a new BOPET line in Ahmedabad,

aligns with the demand for premium and sustainable packaging, enhancing their growth

prospects (PrintWeek India, 2023).

4.7 Discussion of Findings

The findings confirmed that Chiripal’s manufacturing process is a sophisticated, multi-stage

operation supported by advanced technology. The production of BOPP, BOPET, and CPP films

involves tailored processes—extrusion and orientation for oriented films, cast extrusion for

CPP—each optimized for specific food packaging applications. Chiripal’s technological

investments, such as wide-width lines and metallizers, enable high-quality, customized

production, while their sustainability practices, like zero-discharge plants, address

environmental concerns. The diversity of their film portfolio caters to a wide market, from cost-

sensitive snack packaging to premium retort pouches, aligning with the industry’s growth

trajectory.

However, challenges like regulatory compliance and the high cost of biodegradable films

persist, requiring ongoing innovation. Opportunities in smart packaging and market expansion

offer avenues for Chiripal to strengthen their leadership. The qualitative nature of the data

limited access to quantitative metrics like production costs, but the thematic analysis provided

a rich, contextual understanding of Chiripal’s operations, fulfilling the research objectives.

60
4.8 Conclusion

This chapter presented the results of my thematic analysis, detailing Chiripal Poly Films’

manufacturing processes, film types, technological and sustainability practices, and industry

context. The findings highlighted Chiripal’s technical expertise, strategic positioning, and

alignment with market trends, while acknowledging challenges like regulatory pressures and

opportunities in sustainable innovation. By synthesizing secondary data from 20 sources, I

addressed the research objectives, providing a comprehensive, qualitative analysis that sets the

stage for the findings and recommendations in subsequent chapters.

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 Chapter 5: Findings and Conclusion

5.1 Introduction

As I reached the culmination of my research on the manufacturing process of plastic films for

food packaging at Chiripal Poly Films Limited, I felt a sense of accomplishment in piecing

together a detailed picture from secondary and qualitative data. This project, driven by my

curiosity about how everyday items like snack wrappers and retort pouches are produced,

aimed to explore Chiripal’s operations, a leading player in India’s flexible packaging industry.

Chapter 4 presented a thematic analysis of the data, covering Chiripal’s manufacturing

processes, film types, technological and sustainability practices, and industry context. In this

chapter, I synthesize these findings to address the research objectives, reflect on their

implications, and draw conclusions about Chiripal’s role in the sector. The objectives were to

understand the manufacturing process, identify film types and applications, analyze

technological and sustainability practices, and evaluate industry challenges and opportunities.

By consolidating the insights, I aim to highlight Chiripal’s strengths, contributions, and the

broader significance of their work, while acknowledging the limitations of my secondary data

approach (Ebnesajjad, 2012; Mordor Intelligence, 2024).

5.2 Summary of Key Findings

The thematic analysis in Chapter 4 yielded rich insights into Chiripal Poly Films’ operations,

aligning with the research objectives. Below, I summarize the key findings under each

objective, drawing on the qualitative data from 20 secondary sources, including industry

reports, company publications, and academic literature.

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5.2.1 Manufacturing Process at Chiripal Poly Films

My first objective was to understand the manufacturing process of plastic films for food

packaging at Chiripal. The analysis revealed a sophisticated, multi-stage process tailored to

produce BOPP (Biaxially Oriented Polypropylene), BOPET (Biaxially-Oriented Polyethylene

Terephthalate), and CPP (Cast Polypropylene) films. The process comprises five key stages:

• Raw Material Preparation: Chiripal starts with polymer resins—polypropylene for

BOPP and CPP, and polyethylene terephthalate for BOPET. Their backward integration

into PET resin production, with a capacity of 220,000 tons per annum, ensures quality

and supply stability (Chiripal Poly Films, 2023). Additives like slip agents and

antimicrobial agents enhance film properties, aligning with food safety requirements

(Kanatt et al., 2019).

• Extrusion: Resins are melted and extruded through dies to form thin sheets. BOPP and

BOPET use flat-die or tubular extrusion, while CPP employs cast extrusion, cooled on

a chilled roll for flexibility (Springer, 2024). Chiripal’s advanced lines, like the 10.4-

meter BOPP line from Brückner, ensure precision and high output (Packaging South

Asia, 2023).

• Orientation: BOPP and BOPET films undergo biaxial orientation, stretching the sheet

in machine and transverse directions to improve strength and clarity. CPP films skip

this step, retaining their softness (Marsh & Bugusu, 2007). Chiripal’s Brückner and

Dornier equipment optimizes this stage (PrintWeek India, 2023).

• Finishing and Treatments: Films are treated with metallizing, coating, or corona

discharge to add barrier properties, printability, or heat-sealing capabilities. Chiripal’s

wide-width metallizers (up to 3650mm) and coating lines enable customization for food

packaging (Chiripal Poly Films, 2023).

63
 • Quality Control: Rigorous testing for thickness, tensile strength, and food safety

compliance, supported by ISO certifications, ensures reliability (Kanatt et al., 2019).

Automated systems detect defects, maintaining high standards (Chiripal Poly Films,

2023).

This process, executed at Chiripal’s Ahmedabad and Hyderabad plants, reflects their technical

expertise and ability to produce films meeting diverse food packaging needs.

5.2.2 Types of Films and Their Applications

The second objective was to identify the types of films produced and their food packaging

applications. Chiripal’s portfolio includes BOPP, BOPET, and CPP films, each with distinct

properties:

• BOPP Films: Known for clarity and moisture resistance, BOPP films are used for

snacks, biscuits, bakery products, and labels. Their cost-effectiveness and printability

make them ideal for high-volume, visually appealing packaging (Flexipack, 2024).

Chiripal offers variants like matte or heat-sealable BOPP, catering to diverse needs

(Chiripal Poly Films, 2023).

• BOPET Films: With high-temperature resistance and strength, BOPET films are used

for retort pouches, microwaveable packaging, and boil-in-the-bag products. Their

barrier properties against oxygen and light suit premium applications (Springer, 2024).

Chiripal’s metallized BOPET films enhance performance for ready-to-eat meals

(PrintWeek India, 2023).

• CPP Films: Flexible and heat-sealable, CPP films are used for pouches in frozen or

perishable foods, often laminated with BOPP or BOPET for added strength. Their

affordability makes them versatile for products like frozen vegetables (Markets and

Data, 2023).
64
The diversity of Chiripal’s films allows them to serve a broad market, from budget-friendly

wrappers to specialized pouches, reinforcing their leadership in food packaging (Packaging

South Asia, 2023).

5.2.3 Technological and Sustainability Practices

The third objective was to analyze Chiripal’s technological and sustainability practices. The

findings highlighted their competitive edge:

• Technological Innovations: Chiripal’s investment in advanced machinery, such as

Brückner’s 10.4-meter BOPP lines and Dornier’s 8.7-meter BOPET lines, enables high-

volume, high-precision production (PrintWeek India, 2023). Wide-width metallizers

and coating lines allow customization, producing films with enhanced barrier or

printable properties (Chiripal Poly Films, 2023). Their backward integration into PET

resin production ensures supply chain stability, reducing costs and enhancing efficiency

(Packaging South Asia, 2023).

• Sustainability Practices: Both Ahmedabad and Hyderabad plants are zero-discharge

facilities, minimizing environmental impact through wastewater treatment. Waste is

recycled in-house or converted into pellets for third-party use, aligning with circular

economy principles (Chiripal Poly Films, 2023). These initiatives respond to growing

demands for eco-friendly packaging, enhancing Chiripal’s reputation (Springer, 2024).

These practices position Chiripal as a forward-thinking manufacturer, balancing innovation

with environmental responsibility.

5.2.4 Industry Challenges and Opportunities

The fourth objective was to evaluate challenges and opportunities in the plastic film

manufacturing industry, contextualizing Chiripal’s operations:

65
 • Challenges: Regulatory pressures, such as FSSAI standards and single-use plastic bans,

increase compliance costs (Markets and Data, 2023). The high capital investment for

advanced machinery and sustainable practices is a barrier, though Chiripal’s scale

mitigates this (Kanatt et al., 2019). Biodegradable films, while promising, face

scalability and cost issues, limiting adoption (Springer, 2024).

• Opportunities: The Indian plastic packaging film market, valued at 1.80 million tonnes

in 2024 with a 7.26% CAGR through 2030, offers growth potential driven by

urbanization and e-commerce (Mordor Intelligence, 2024). Innovations like

antimicrobial films and smart packaging present differentiation opportunities, where

Chiripal’s technology positions them well (Kanatt et al., 2019). Their expansion,

including a new BOPET line in Ahmedabad, aligns with demand for premium

packaging (PrintWeek India, 2023).

These findings highlight Chiripal’s ability to navigate challenges while capitalizing on market

opportunities.

5.3 Discussion of Findings

The findings provide a comprehensive understanding of Chiripal’s operations, fulfilling the

research objectives and addressing the research problem—a lack of company-specific studies

on their manufacturing processes. Below, I discuss the implications of each objective,

connecting the findings to the broader industry context.

5.3.1 Manufacturing Process Insights

The detailed mapping of Chiripal’s manufacturing process was one of the most rewarding

aspects of this study. The five-stage process—raw material preparation, extrusion, orientation,

finishing, and quality control—demonstrates a blend of technical precision and operational

scale. The use of advanced equipment, like Brückner and Dornier lines, ensures high-quality
66
films, while backward integration into PET resin production optimizes efficiency (Packaging

South Asia, 2023). This process aligns with industry standards, as described by Ebnesajjad

(2012), but Chiripal’s scale and customization capabilities set them apart.

The process’s adaptability to produce BOPP, BOPET, and CPP films highlights Chiripal’s

versatility. For instance, the orientation stage, critical for BOPP and BOPET, enhances barrier

properties, while CPP’s cast extrusion prioritizes flexibility (Springer, 2024). Quality control,

supported by ISO certifications, ensures compliance with food safety standards, a crucial factor

in food packaging (Chiripal Poly Films, 2023). These findings address the research problem

by providing a detailed, company-specific analysis, filling a gap in the literature.

5.3.2 Film Types and Market Relevance

Identifying Chiripal’s film types and applications underscored their market relevance. BOPP’s

dominance in cost-effective applications like snacks reflects its affordability and printability,

while BOPET’s use in premium retort pouches leverages its strength and thermal stability

(Flexipack, 2024). CPP’s role in flexible pouches complements these, offering heat-sealing

capabilities (Markets and Data, 2023). Chiripal’s ability to produce all three films positions

them as a one-stop supplier, catering to diverse customer needs, from budget brands to premium

manufacturers (Packaging South Asia, 2023).

This diversity aligns with the growing Indian market, where demand for packaged foods is

rising due to urbanization and e-commerce (Mordor Intelligence, 2024). The findings highlight

Chiripal’s strategic alignment with market trends, reinforcing their leadership and addressing

the objective of understanding their product portfolio’s applications.

5.3.3 Technological and Sustainability Leadership

Chiripal’s technological and sustainability practices were among the most compelling findings.

Their investment in wide-width machinery and customization capabilities, like metallizers and
67
coating lines, enables them to produce specialized films, meeting varied food packaging

requirements (PrintWeek India, 2023). Backward integration into PET resin production

enhances efficiency, a strategic move that mitigates supply chain risks (Packaging South Asia,

2023).

Their sustainability initiatives, particularly zero-discharge plants and waste recycling, respond

to global and local demands for eco-friendly packaging (Springer, 2024). These practices not

only reduce environmental impact but also strengthen Chiripal’s brand as a responsible

manufacturer, aligning with consumer and regulatory expectations (Chiripal Poly Films, 2023).

The findings fulfill the objective of analyzing these practices, highlighting Chiripal’s forward-

thinking approach in a competitive industry.

5.3.4 Navigating Industry Dynamics

The evaluation of industry challenges and opportunities contextualized Chiripal’s operations.

Regulatory pressures, such as FSSAI compliance and plastic bans, pose challenges, but

Chiripal’s certifications and scale enable them to adapt (Markets and Data, 2023). The high

cost of biodegradable films remains a hurdle, yet Chiripal’s recycling initiatives position them

to explore sustainable alternatives (Springer, 2024).

Opportunities in the growing Indian market and innovations like antimicrobial films offer

significant potential. Chiripal’s technological capabilities and expansion plans, such as the new

BOPET line, align with these trends, ensuring they remain competitive (Mordor Intelligence,

2024; PrintWeek India, 2023). These findings address the objective of evaluating industry

dynamics, providing a balanced view of Chiripal’s challenges and prospects.

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5.4 Implications of the Findings

The findings have several implications for stakeholders in the plastic film and food packaging

industry:

• For Chiripal Poly Films: The study highlights their strengths in technology,

sustainability, and market positioning, suggesting they continue investing in

innovations like biodegradable films and smart packaging. Their sustainability

practices could be leveraged for marketing to enhance brand value.

• For the Industry: Chiripal’s model of backward integration and zero-discharge

facilities offers a blueprint for other manufacturers seeking to balance efficiency and

environmental responsibility. Their success underscores the importance of

technological investment in meeting market demands.

• For Policymakers: The challenges of regulatory compliance and biodegradable film

adoption suggest a need for supportive policies, such as subsidies for sustainable

technologies or clearer recycling guidelines.

• For Researchers: The study fills a gap in company-specific analyses, encouraging

further research into other manufacturers or primary data studies to complement

secondary findings.

These implications highlight the broader significance of Chiripal’s operations, extending

beyond the company to influence industry practices and policy.

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5.5 Limitations of the Study

Reflecting on the study, I acknowledge several limitations inherent in the secondary, qualitative

approach:

• Reliance on Secondary Data: The absence of primary data, such as interviews with

Chiripal’s staff, limited access to proprietary details like production costs or specific

defect rates. This constrained the depth of some findings (Ebnesajjad, 2012).

• Source Specificity: While sources like Packaging South Asia (2023) provided valuable

insights, some lacked granular details about Chiripal’s processes, requiring inference

based on industry standards.

• Qualitative Focus: The qualitative nature precluded quantitative metrics, which could

have added precision but were inaccessible in public sources (Mordor Intelligence,

2024).

• Scope Restriction: Focusing solely on Chiripal prevented comparisons with

competitors like UFlex, which could have enriched the analysis (Markets and Data,

2023).

Despite these limitations, the use of 20 credible sources and thematic analysis ensured a robust,

comprehensive study, addressing the research objectives effectively.

5.6 Conclusion

This project deepened my understanding of the manufacturing process of plastic films for food

packaging at Chiripal Poly Films Limited, fulfilling the research objectives and addressing the

research problem. The findings revealed a sophisticated, multi-stage process producing BOPP,

BOPET, and CPP films, supported by advanced technology and rigorous quality control.

Chiripal’s diverse film portfolio caters to a wide range of food packaging needs, from snacks

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to retort pouches, aligning with the growing Indian market. Their technological innovations,

like wide-width machinery, and sustainability practices, such as zero-discharge plants, position

them as a leader in the industry. Despite challenges like regulatory pressures, opportunities in

market growth and innovation offer significant potential.

The study’s reliance on secondary, qualitative data was both a strength and a limitation. It

allowed me to construct a detailed narrative from credible sources, but the lack of primary data

restricted specificity. Nevertheless, the findings contribute to the limited literature on company-

specific manufacturing processes, offering insights for Chiripal, the industry, and future

researchers. This project not only satisfied my curiosity but also highlighted the critical role of

plastic films in food packaging, underscoring Chiripal’s contributions to a vital sector. The

interplay of technology, sustainability, and market dynamics in their operations is a testament

to their strategic vision, paving the way for continued leadership in the industry.

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 Chapter 6: Recommendations and Limitations of the Study

6.1 Introduction

As I concluded my research on the manufacturing process of plastic films for food packaging

at Chiripal Poly Films Limited, I felt both fulfilled by the insights gained and aware of the

boundaries of my study. The previous chapters detailed the manufacturing process marked by

advanced technology, a diverse film portfolio, and a strong focus on sustainability, positioning

Chiripal as a leader in India’s flexible packaging industry. Chapter 5 synthesized these findings,

highlighting how Chiripal’s operations align with market demands and industry trends. In this

chapter, I present recommendations for Chiripal Poly Films, the broader packaging industry,

and future researchers, aiming to build on the study’s findings to enhance practices and

knowledge in the field. Additionally, I reflect on the limitations of my research, particularly the

constraints of relying solely on secondary and qualitative data. These recommendations and

limitations are grounded in the qualitative insights from 20 credible sources, including industry

reports, company publications, and academic literature, ensuring they are both practical and

relevant to the research objectives (Ebnesajjad, 2012; Mordor Intelligence, 2024).

6.2 Recommendations

The findings from my study offer several opportunities for Chiripal Poly Films, the packaging

industry, and future researchers to advance their practices and understanding of plastic film

manufacturing for food packaging. Below, I outline recommendations tailored to each

stakeholder group, addressing technological innovation, sustainability, market strategies, and

research approaches.

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6.2.1 Recommendations for Chiripal Poly Films

Based on the analysis of Chiripal’s operations, I propose the following recommendations to

strengthen their position and address industry challenges:

• Invest in Biodegradable and Compostable Films: The growing demand for

sustainable packaging, as noted by Springer (2024), presents an opportunity for

Chiripal to explore biodegradable films like polylactic acid (PLA) composites or

polyhydroxyalkanoates (PHA). While scalability and cost remain challenges, Chiripal’s

technological capabilities and scale could support pilot projects to develop cost-

effective biodegradable films for food packaging. For instance, they could target niche

applications like organic food packaging, where consumers prioritize eco-friendly

options. This aligns with their existing sustainability initiatives, such as zero-discharge

plants, and could enhance their brand as an environmental leader (Chiripal Poly Films,

2023).

• Enhance Transparency and Public Communication: Chiripal’s advanced processes

and sustainability practices, like waste recycling and backward integration, are

significant strengths, but public awareness is limited, as seen in the scarcity of detailed

company-specific literature (Packaging South Asia, 2023). I recommend that Chiripal

publish more detailed, non-proprietary information about their manufacturing

processes, technologies, and environmental impact through annual sustainability

reports or case studies on their website. This transparency could attract eco-conscious

brands and strengthen partnerships with converters, while also contributing to industry

knowledge (Markets and Data, 2023).

• Collaborate on Research and Development (R&D): To stay ahead of innovations like

antimicrobial films and smart packaging, Chiripal could partner with academic

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 institutions or research organizations, as suggested by Kanatt et al. (2019). For example,

collaborating with Indian Institutes of Technology (IITs) on developing films with

natural antimicrobial agents could enhance food safety and shelf life, aligning with

consumer trends toward clean-label products. Such partnerships could also access

government funding for sustainable packaging research, reducing R&D costs (Springer,

2024).

• Expand Smart Packaging Capabilities: The industry’s move toward smart packaging,

with sensors for freshness or temperature monitoring, offers a growth opportunity

(Kanatt et al., 2019). Chiripal’s coating lines and technological expertise position them

to integrate such features into their films. I recommend investing in pilot projects for

smart BOPET films for premium products like ready-to-eat meals, leveraging their

export markets in North America and Europe, where demand for innovative packaging

is high (Chiripal Poly Films, 2023).

• Strengthen Workforce Training: The complexity of Chiripal’s manufacturing

processes, such as biaxial orientation and metallizing, requires skilled operators

(PrintWeek India, 2023). I suggest implementing regular training programs to upskill

employees on advanced machinery and sustainability practices. This could improve

efficiency, reduce defects, and ensure compliance with evolving regulations like FSSAI

standards, enhancing overall operational performance (Markets and Data, 2023).

These recommendations aim to build on Chiripal’s strengths—technological leadership,

sustainability, and market reach—while addressing challenges like regulatory pressures and the

need for sustainable innovation.

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6.2.2 Recommendations for the Packaging Industry

The broader packaging industry can benefit from Chiripal’s practices and the study’s insights.

I propose the following:

• Adopt Backward Integration Models: Chiripal’s backward integration into PET resin

production ensures supply chain stability and cost efficiency (Packaging South Asia,

2023). Other manufacturers, particularly mid-sized firms, could explore similar

strategies, such as in-house additive production or resin compounding, to reduce

dependency on external suppliers and enhance competitiveness (Ebnesajjad, 2012).

• Prioritize Zero-Discharge Facilities: Chiripal’s zero-discharge plants set a benchmark

for environmental responsibility (Chiripal Poly Films, 2023). I recommend that

industry players invest in wastewater treatment and waste recycling systems to meet

regulatory requirements and consumer expectations for sustainability. Industry

associations could facilitate knowledge-sharing on cost-effective zero-discharge

technologies (Springer, 2024).

• Develop Industry-Wide Standards for Biodegradable Films: The high cost and

scalability issues of biodegradable films are a common challenge (Springer, 2024). I

suggest that industry bodies like the Flexible Packaging Association of India

collaborate to establish standards for biodegradable films, streamline production

processes, and lobby for government incentives to reduce costs. This could accelerate

adoption across the sector (Mordor Intelligence, 2024).

• Leverage Technology for Customization: Chiripal’s use of wide-width metallizers

and coating lines for customized films highlights the value of flexible manufacturing

(PrintWeek India, 2023). Other manufacturers should invest in modular equipment that

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 allows rapid adjustments to film properties, enabling them to meet diverse customer

needs, from high-barrier to printable films (Flexipack, 2024).

These recommendations encourage the industry to adopt best practices from leaders like

Chiripal, fostering innovation and sustainability.

6.2.3 Recommendations for Future Researchers

For researchers interested in plastic film manufacturing or food packaging, I offer the following

suggestions to build on this study:

• Incorporate Primary Data: My reliance on secondary data limited access to

proprietary details (Ebnesajjad, 2012). Future researchers could conduct primary

research, such as interviews with Chiripal’s engineers or site visits to their Ahmedabad

and Hyderabad plants, to gain deeper insights into process specifics, defect rates, or

cost structures. This would complement secondary findings and provide a more

granular analysis (Saunders et al., 2019).

• Compare Multiple Manufacturers: Focusing solely on Chiripal restricted

comparative analysis (Markets and Data, 2023). I recommend that future studies

compare Chiripal with competitors like UFlex or Jindal Poly Films to identify best

practices, technological differences, and sustainability approaches. This could reveal

industry-wide trends and competitive dynamics (Packaging South Asia, 2023).

• Explore Quantitative Metrics: The qualitative focus of my study precluded

quantitative data like production costs or energy consumption (Mordor Intelligence,

2024). Future research could use quantitative methods, such as cost-benefit analyses of

biodegradable films or energy audits of manufacturing processes, to add precision and

economic insights (Bryman, 2016).

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 • Investigate Consumer Perceptions: The study focused on manufacturing processes,

but consumer perceptions of plastic films, especially regarding sustainability, are

critical (Springer, 2024). Researchers could conduct surveys or focus groups to explore

how consumers view Chiripal’s films versus biodegradable alternatives, informing

marketing and product development strategies (Kanatt et al., 2019).

• Examine Policy Impacts: Regulatory pressures, such as single-use plastic bans,

significantly affect the industry (Markets and Data, 2023). Future studies could analyze

the impact of policies like India’s Plastic Waste Management Rules on manufacturers

like Chiripal, assessing compliance costs and opportunities for policy advocacy

(Mordor Intelligence, 2024).

These recommendations aim to address the gaps in my study and expand the knowledge base

on plastic film manufacturing.

6.3 Limitations of the Study

Reflecting on my research, I acknowledge several limitations that shaped the scope and depth

of the findings. These limitations, primarily due to the reliance on secondary and qualitative

data, are discussed below to provide context for the study’s conclusions and guide future

research.

6.3.1 Reliance on Secondary Data

The exclusive use of secondary data was a significant limitation. While sources like Packaging

South Asia (2023), Chiripal Poly Films (2023), and Mordor Intelligence (2024) provided

valuable insights, I couldn’t access proprietary or firsthand information, such as detailed

process parameters, production costs, or defect rates. For example, while I described Chiripal’s

extrusion and orientation stages, specifics like temperature settings or stretching ratios were

unavailable in public sources (Ebnesajjad, 2012). Primary data, such as interviews with
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Chiripal’s engineers or site visits, would have added depth but was beyond my resources as a

student. This limitation restricted the granularity of the findings, particularly in technical

aspects of the manufacturing process.

6.3.2 Limited Source Specificity

Another limitation was the lack of highly specific information about Chiripal’s operations in

some sources. Industry reports, such as those from PrintWeek India (2023), offered general

updates on Chiripal’s facilities or capacities but often lacked detailed process descriptions or

operational challenges. Academic literature, like Springer (2024), provided technical insights

into film manufacturing but rarely focused on individual companies. As a result, I had to infer

certain details, such as the exact role of additives in Chiripal’s films, based on industry

standards (Kanatt et al., 2019). This inference, while grounded in credible sources, introduced

a degree of uncertainty in some findings.

6.3.3 Qualitative Focus

The qualitative nature of the study precluded quantitative metrics, which could have enhanced

precision. For instance, I couldn’t access data on Chiripal’s production costs, energy

consumption, or waste recycling rates, which are often proprietary (Mordor Intelligence, 2024).

While qualitative data allowed a rich, contextual analysis of processes, technologies, and

sustainability practices, quantitative metrics would have provided concrete benchmarks, such

as the cost-effectiveness of zero-discharge plants or the efficiency of backward integration

(Markets and Data, 2023). This limitation reflects the constraints of secondary data and the

scope of a student project.

6.3.4 Scope Restriction to Chiripal

Focusing solely on Chiripal Poly Films limited the study’s ability to compare their practices

with competitors like UFlex or Jindal Poly Films. Such comparisons could have highlighted
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Chiripal’s unique strengths or areas for improvement, enriching the analysis (Packaging South

Asia, 2023). However, the decision to focus on Chiripal was driven by the research problem—

a lack of company-specific studies—and the need to maintain a manageable scope within the

project’s timeline. This restriction meant that industry-wide trends were discussed broadly,

without detailed benchmarking against other manufacturers.

6.3.5 Time and Resource Constraints

The project’s timeline and resource limitations as a student further constrained the study. With

only 20 sources analyzed, I reached data saturation for the qualitative objectives, but a longer

timeframe could have allowed a broader literature review or exploration of additional sources,

such as international journals or trade publications (Bryman, 2016). Additionally, the inability

to conduct primary research due to logistical and financial constraints limited the depth of some

findings, particularly regarding Chiripal’s operational challenges or employee perspectives

(Saunders et al., 2019).

6.3.6 Potential Bias in Secondary Sources

Secondary sources, especially industry reports and company publications, may contain biases,

such as promotional content or selective reporting. For example, Chiripal’s website emphasized

their sustainability achievements, like zero-discharge plants, but provided less detail on

challenges or costs (Chiripal Poly Films, 2023). While I mitigated this by cross-verifying

information across multiple sources, including academic literature and independent reports,

some bias may persist, affecting the objectivity of certain findings (Ebnesajjad, 2012).

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6.4 Mitigating the Limitations

Despite these limitations, I took steps to ensure the study’s rigor and reliability:

• Diverse Source Selection: Using 20 sources, including academic literature (e.g.,

Springer, 2024), industry reports (e.g., Mordor Intelligence, 2024), and company

publications, provided a balanced perspective and reduced reliance on any single

source.

• Cross-Verification: Information was cross-checked across sources to enhance

accuracy. For instance, Chiripal’s Hyderabad plant capacity was confirmed by both

Packaging South Asia (2023) and Chiripal Poly Films (2023).

• Thematic Analysis: The systematic use of thematic analysis ensured that findings were

grounded in the data, with themes like manufacturing processes and sustainability

practices clearly linked to source evidence (Braun & Clarke, 2006).

• Transparent Reporting: I explicitly acknowledged assumptions or inferences, such as

estimated distributions in figure, to maintain transparency (Chapter 4).

These measures strengthened the study’s credibility, allowing it to fulfill the research objectives

despite the constraints.

6.5 Implications for Future Research

The limitations highlight several directions for future research to build on this study:

• Primary Data Collection: Conducting interviews or site visits at Chiripal’s facilities

could provide firsthand insights, addressing the gap in proprietary data (Saunders et al.,

2019).

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 • Comparative Studies: Analyzing multiple manufacturers would offer a broader

industry perspective, identifying best practices and competitive advantages (Packaging

South Asia, 2023).

• Quantitative Analysis: Incorporating metrics like production costs or environmental

impact would add precision, complementing qualitative findings (Mordor Intelligence,

2024).

• Sustainability Focus: Exploring the feasibility of biodegradable films or the long-term

impact of zero-discharge plants could deepen understanding of sustainable packaging

(Springer, 2024).

• Global Context: Examining Chiripal’s operations in the context of global competitors

could highlight their international competitiveness and export strategies (Chiripal Poly

Films, 2023).

These directions would address the study’s limitations and contribute to a more comprehensive

knowledge base.

6.6 Conclusion

This chapter presented recommendations and limitations for my study on Chiripal Poly Films’

manufacturing process for plastic films in food packaging. The recommendations for

Chiripal—investing in biodegradable films, enhancing transparency, collaborating on R&D,

expanding smart packaging, and strengthening workforce training—build on their strengths to

address industry challenges and opportunities. For the packaging industry, adopting backward

integration, zero-discharge facilities, and standardized biodegradable films can drive

sustainability and competitiveness. Future researchers are encouraged to incorporate primary

data, compare manufacturers, and explore quantitative metrics to deepen insights.

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The limitations, including reliance on secondary data, limited source specificity, qualitative

focus, scope restriction, time constraints, and potential source bias, shaped the study’s scope

but were mitigated through diverse sourcing, cross-verification, and transparent reporting.

These limitations highlight the need for further research to complement this study’s qualitative

findings. Overall, this project not only achieved its objectives but also contributed to the limited

literature on company-specific manufacturing processes, offering valuable insights for

Chiripal, the industry, and academia. The recommendations and future research directions pave

the way for continued advancements in the plastic film industry, ensuring it meets the evolving

demands of food packaging and sustainability.

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• Chiripal Poly Films Limited. (2023). Company website and LinkedIn page.

https://www.chiripalpolyfilms.in/

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• PrintWeek India. (2023, April 10). Made in India: Flexible packaging films from

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