When TCPL first launched its flexible packaging unit a year ago, in September 2016, the company was among the leading players in the monocarton manufacturing market. But flexible packaging being an entirely different kettle of fish and the company with very little experience, it was uncharted waters. Nevertheless, today the company has come a long way from those uncertain days with its flexible packaging unit continuing to grow at a steady pace.
Powering the flexible packaging unit are ultra-modern packaging equipment. For example, the unit currently employs a Bobst Rotomec RS4003 MP 9-color gravure press with a novel UV coater, twin Nordmeccanica SuperCombi 3000, apart from a Goebel slitter rewinder and an Ultraflex slitter rewinder.
Speaking about the status of the flexible packaging unit of his company, Saket Kanoria, MD, TCPL, said that the launch of new and innovative flexible packaging products has been a roller coaster journey with great learning opportunities for all involved. “One reason why the journey was uneven also had to do with the fact that we were trying a lot of new ideas and concepts for fresh innovations,” said Kanoria
Kanoria also appeared upbeat about the prospects of the Silvassa unit and cited the feedback of customers who have visited the plant as a reason for that. He said, “Customer feedback to our plant has been largely positive, with many of them going ahead and putting commercial orders. A significant number are in the negotiation stage as well.” He offered optimism that the unit will soon earn the coveted BRC rating, having already won the ISO9000, ISO14000 and ISO15000 ratings. Another thing going right for the unit is its impressive GMP ratings.
Kanoria informed us that its Silvassa unit at the moment is only operating at half its full potential with a total monthly installed capacity to the tune of 400 tonnes.
One working principle adopted by TCPL in the last year or so has been to invest in value addition including haptics and soft touch coatings for FMCG products and other goods. Kanoria said that to take care of these special jobs, the carton wing of the company worked in close coordination with its flexible packaging division. The unit in addition received assistance from ink and machine manufacturers.
Since these special jobs involve matte coating and spot UV, TCPL is collaborating with three SKUs from the chewing and tobacco industry to give the finished products a more realistic look. Kanoria said, “ The project is still in the production stage and it won’t be until Diwali that the commercial launch would happen.”
Since without the first order in place, it is difficult to approach other customers, Kanoria said that it is important that the products get the initial breakthrough. “Once the product is in the market, it is much easier to sell it to other customers,” he added. The company also plans to include new industries in the existing list for these special jobs.”
The flexible packaging unit, in addition to these special jobs, has also dabbled in shrink sleeves in the past one year as it tries to diversify its portfolio. Both cut and reel forms of these sleeves are available to customers. For shrink sleeves, the company has installed a Freschi sleeving machine. TCPL is also taking the help of Esko WebCentre, a web-based platform that is both easy to use and efficient, in a bid to cut down on errors and speed up approvals. The software is also useful for managing packaging pre-production specifications and the life cycle of products.
On a parting note, Kanoria said that in the next fiscal year, the capacity of the flexible packaging unit will be doubled. There is scope for at least two gravure lines in the Silvassa plant, along with other finishing equipment and laminators, he added.
Mahan Hazarika
