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UFlex opens $126m aseptic carton plant in Egypt, doubling global capacity

UFlex has inaugurated a $126 million greenfield Asepto aseptic carton facility at Ain Sokhna, Egypt, with eventual annual capacity of 12 billion packs, taking the Indian group's combined global aseptic capacity to about 24 billion packs a year alongside its Sanand plant in India. The Egyptian plant is expected to start at around 30% utilisation and progressively ramp toward full capacity by around 2030, targeting Europe, Africa, the Gulf, the Americas and the CIS via Suez Canal shipping routes.

Why this mattersA second, closer-to-market aseptic base gives UFlex a route to compete more directly with Tetra Pak, SIG and Elopak in Europe, Africa and the Gulf.

  • Investment: $126 million greenfield Asepto plant at Ain Sokhna, Egypt, on a 30-acre site
  • Eventual annual capacity: 12 billion aseptic carton packs, matching UFlex's Sanand plant in India
  • Combined global aseptic capacity reaches approximately 24 billion packs per year
  • Initial utilisation expected at roughly 30%, rising to about 70% in year two and design capacity by 2030
  • The plant has entered customer trials, with commercial production planned for late 2026
  • Egypt trade access includes COMESA, GAFTA and the African Continental Free Trade Area
  • The Ain Sokhna plant is equipped with two Heidelberg Boardmaster printing lines, an SML extrusion line and two IMS slitters.
  • Utilisation is now phased at about 30% in year one and 60-70% in year two, with full capacity targeted around 2029-30.
  • UFlex reported group revenue of about $1.63 billion for the year ended 31 March, with more than 16,000 employees globally.
  • More than $100 million of the $126 million investment has already been spent.
  • UFlex frames the Egypt plant as a shift from an India-led export model to multi-location global manufacturing
  • The plant uses a Heidelberg Board Master XL 1650 printing line and an SML Triplex extrusion laminator.
  • Paper for the plant is supplied by Stora Enso.
  • Asepto's existing Sanand, India plant serves over 250 customers in more than 50 countries.
  • Utilisation is now guided at 30% in year one, rising to 100% by year three.
  • The Ain Sokhna plant uses automated manufacturing machinery
  • The Ain Sokhna plant sits in the Orascom Industrial Park within the Suez Canal Economic Zone.
  • Installed equipment includes a Heidelberg Boardmaster XL 1650 press, an SML Triplex lamination line and Madern Automation reel handling rated at 160 reels an hour.
  • Commercial trials are underway ahead of commissioning, still targeted before the end of 2026.
  • The Ain Sokhna plant will use next-generation automated manufacturing machinery
  • UFlex's Q1 FY27 consolidated net profit rose 629.6% year-on-year to INR 423.3 crore
  • Q1 FY27 revenue rose 37.6% year-on-year to INR 5,366 crore
SIG Group mentioned Elopak mentioned Greatview Aseptic Packaging mentioned Tetra Pak mentioned Stora Enso counterparty UFlex
Sources business-news-today.com packaginginsights.com es.wedoany.com ES economictimes.indiatimes.com 103news.com packagingsouthasia.com bladeintel.com economictimes.indiatimes.com in-food.co.uk economictimes.indiatimes.com agronfoodprocessing.com
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Written by AI from the sources above and checked by a second AI system before publication. No human wrote or edited this story. How it is made.

Updates

  • 2026-09-16 · Edited before publication: The Q1 FY2027 revenue and net profit figures (INR 5,366 crore, INR 423 crore) appear nowhere in the excerpts. Removed and replaced with the ramp profile and commercial-production timing from the Spanish source, which are grounded.
  • 2026-09-18 · Update: UFlex details further specifics of the Egypt aseptic plant, including production equipment and a revised utilisation ramp, as the facility remains in customer trials ahead of commercial production.
  • 2026-09-19 · Update: UFlex reiterates the Ain Sokhna, Egypt Asepto plant investment of USD 126m and confirms combined India-Egypt aseptic capacity of 24 billion packs a year as it moves to a multi-location manufacturing model.
  • 2026-09-22 · Update: UFlex says the Ain Sokhna plant is now in commercial trials ahead of end-2026 commissioning, running a Heidelberg Board Master XL 1650 line and an SML Triplex laminator with Stora Enso paper, as Asepto's Sanand, India site continues serving over 250 customers in more than 50 countries.
  • 2026-09-23 · Update: UFlex confirms the USD 126m Ain Sokhna aseptic plant's stated 12 billion-pack capacity and export markets, and discloses the site uses automated manufacturing machinery.
  • 2026-09-25 · Update: UFlex confirms commercial trials are underway at the Ain Sokhna plant, with commissioning still targeted before the end of 2026 and specifics on the installed equipment.
  • 2026-09-26 · Update: UFlex confirms the Ain Sokhna aseptic carton plant will run next-generation automated machinery to supply Europe, Africa, the GCC, CIS and the Americas.
  • 2026-09-29 · Update: UFlex reports Q1 FY27 consolidated net profit up 629.6% year-on-year to INR 423.3 crore as its Egypt aseptic plant, previously inaugurated with USD 126m investment, continues ramp-up alongside a re-confirmed 20-year Indian patent for its twin aseptic packaging machine.