Expanding global manufacturing base for flexible packaging

Cosmo Films expands and installed a cutting-edge, high-speed slitter rewinder at its Carol Stream Warehouse in Chicago. The new equipment reduces the lead-time, ensuring that Cosmo Films can rapidly respond to growing demand and better support its North American partners’ production timelines. In an exclusive interview with the Internation Plastics News for Asia, Sandeep Dutta, President North America of Cosmo Films, explains about the expansion at the Chicago facility and how strategically positioned site serves all major North American markets, including the United States and Canada.

Sandeep Dutta, President North America, Cosmo Films

Sandeep Dutta has more than three-decades of experience in Project Management, Plant Engineering, Procurement & Logistics, Manufacturing, Business Development and Sales and Marketing in the polymer film industry with deep knowledge of BOPP, CPP, PET, top-coated and metallized films.

What is the strategy behind the expansion in Cosmo Films USA? Please elaborate.

Mr. Dutta: The expansion in Cosmo Films USA is driven by a clear strategy to meet the dynamic and evolving needs of the North American flexible packaging market, which is witnessing robust growth. Cosmo’s goal is to deliver enhanced customer service, faster delivery, and just-in-time solutions—which reduce order fulfilment timeline from 2-3 months to just 10-15 days. By investing in state-of-the-art infrastructure and technology, the company is empowering its partners across sectors to optimise inventory, reduce warehousing costs, and achieve supply chain agility. This approach positions Cosmo Films as a valuable extended platform of its global manufacturing base, allowing it to deepen customer relationships and deliver innovation, quality, and speed to market throughout the continent.

The Chicago facility is strategically positioned to serve all major North American markets, including the United States, Canada. Its central location and advanced infrastructure ensure prompt delivery of specialised packaging films wherever customers operate on the continent.

What new equipment is installed at the Chicago-based site?

Mr. Dutta: Cosmo Films has installed a cutting-edge, high-speed slitter rewinder at its Carol Stream Warehouse in Chicago. This new equipment is 120 inches wide and offers high-precision, high-speed operation (up to 3,000 feet per minute). It represents Cosmo Films’ commitment to technological excellence and capability, enabling the company to process a diverse range of substrates with exceptional accuracy and reliability.

Cosmo Films’ expansion at the Chicago facility is strategically positioned site to serve all major North American markets, including the United States and Canada.

The installation of this slitter rewinder marks a significant new development in Cosmo Films’ onsite capabilities. Previously, order lead times spanned 2-3 months, but the new equipment allows for fulfilment in just 10–15 days. The investment ensures that Cosmo Films can rapidly respond to growing demand and better support its North American partners’ production timelines and business goals.

Will the new equipment also improve product quality? If yes, please explain.

Mr. Dutta: Absolutely. The advanced slitter rewinder delivers razor-sharp precision and ultra-fast operation, resulting in superior edge quality, reduced material waste, and consistent finishing for all film types. These engineering enhancements ensure every cut meets exacting industry standards, helping Cosmo Films uphold its global reputation for quality and performance in packaging and converting solutions.

Prior to this expansion, there was slitting capability in the US with three narrow web slitters (63” wide)  with ability to slit rolls only on 3” cores with a maximum roll diameter of 13”.  The new wide web high speed slitter enables the conversion of BOPP / CPP / BOPET films on 6” cores and to a maximum roll diameter of 40”. This will open our ability to service large consumers of films who have refrained from buying from Cosmo films due to the long lead times.

Explain the features of the new slitter line. Is it sourced locally or an imported variant?

Mr. Dutta: The new slitter is engineered with a 120-inch operational width and advanced controls for precision slitting at speeds up to 3,000 feet per minute. It is a state-of-the-art machine which has been manufactured in Europe by a leading OEM, with a legacy of supplying high quality Slitting equipment to various film manufacturers and It is capable of processing multiple substrates including BOPP, CPP, BOPET, and PETG both on 3” as well as 6” cores to a maximum of 40” roll Diameter of the finished rolls. The machine is designed to maximize accuracy, reduce changeover time, and ensure reliability. Cosmo Films consistently partners with globally recognized technology manufacturers for these strategic machine investments.

How does the new line help achieve shorter production and delivery schedules?

Mr. Dutta: Thanks to the speed and flexibility of the new slitter, Cosmo Films can now complete and deliver most customer orders within 10–15 days from receipt, a vast improvement over the previous timelines. This rapid turnaround optimises customers’ workflow, inventory management, and production planning, giving them a competitive edge in their markets.

The new slitter line can process a wide array of substrates: BOPP, CPP, BOPET, and PETG films. Its operational speed—up to 3,000 feet per minute—makes it ideal for handling high-volume, high-performance packaging requirements while maintaining consistent quality.

This slitter enables the conversion of BOPP, CPP and BOPET films for packaging applications which goes into laminates for sachets, pouches, wraps, and Label face stock films—all vital in food, beverage, personal care, healthcare, and pharma sectors. Cosmo Films’ product portfolio also includes advanced barrier metallized films and chemical-coated solutions, optimising shelf life, protection, and visual appeal for consumer-facing brands.

Cosmo Films’ product portfolio also includes advanced barrier metallized films and chemical-coated solutions.

What is the current growth level of Cosmo Films in the US market and, with expansion, the growth it aims to achieve in the ongoing calendar? What more steps are being undertaken to create smarter supply chain?

Mr. Dutta: Cosmo Films continues to achieve consistent year-over-year growth in the US market, which remains a strategic priority. With this expansion, the company aims to accelerate growth further by delivering rapid service, expanded product offerings, and advanced technical solutions to meet evolving market needs and customer expectations.

The US operation is fundamental to Cosmo Group’s global vision—it connects its manufacturing platforms to the world’s largest flexible packaging market and drives innovation in supply chain management. We continue to upgrade infrastructure, deploy advanced warehousing, and integrate digital technologies to enable real-time service, flexibility, and bespoke film development for local partners.

What products are produced at the Chicago site and what new products are in the pipeline?

Mr. Dutta: The Chicago site currently supplies a full range of specialty packaging, label and lamination films: clear, white, metallized, and coated ( acrylic / PvDC) BOPP; CPP and BOPET films; and barrier and chemical-coated options. Newly developed products include high-barrier label films, eco-friendly graphic alternatives, PVC-free replacement Green Graphic Films and other specialty solutions designed for the latest market trends and customer requirements.

What are the evolving challenges, opportunities and trends in the North American packaging market that Cosmo Films is preparing for?

Mr. Dutta: North America is undergoing rapid transformation in packaging—driven by sustainability, customization, regulatory shifts, and consumer preference. Cosmo Films welcomes these challenges as opportunities to innovate, introducing environmentally sound, high-performance packaging and working with brands to create holistic, value-driven solutions in a critical and developed market.

Key trends include recyclable/post-consumer packaging, bio-based and high-barrier films, aesthetic differentiation, and smarter solutions with digital integration. Cosmo Films is advancing R&D and launching fresh specialty films—from PVC-free to functional and sustainable films—to address these trends and ensure customers are equipped for future success.