TCPL Packaging is strengthening its position in gravure printing infrastructure through its subsidiary Accura Technik (ATPL), which is expanding its gravure cylinder manufacturing and engraving facility at Silvassa in Gujarat. The company plans to complete the expansion before December 2026, effectively doubling the plant’s existing capacity.

Commissioned in November 2025 following an investment of around INR 50 crore, the Silvassa facility was established to serve both TCPL Packaging’s internal requirements and the wider gravure printing industry. Its location gives the company access to the packaging and printing ecosystem in western India, while also offering logistical advantages and access to skilled manpower.

According to Saket Kanoria, managing director of TCPL Packaging, the facility is currently operating at around 75% utilization, with production divided approximately equally between TCPL’s requirements and external customers. As additional capacity comes on stream, the company expects the share of third-party business to increase. The expansion is therefore aimed not only at supporting TCPL’s growing cylinder requirements but also at developing ATPL into an independent supplier to the wider packaging market.

Integrated cylinder manufacturing

ATPL’s Silvassa plant has been designed as an integrated facility covering the major stages of gravure cylinder production, including cylinder preparation, copper and chrome plating, polishing, engraving and proofing. The facility incorporates laser as well as electronic/stylus engraving technologies, supported by automated polishing and cutting systems. This combination allows the plant to cater to different cylinder specifications and applications, ranging from flexible packaging to cigarette cartons.

Production begins with steel cylinders, which are cleaned and degreased before undergoing surface preparation and copper plating. The copper surface is subsequently polished to achieve the required finish before the cylinder moves to the engraving stage. The plant also has dedicated areas for cylinder storage, inspection and quality control. Surface defects, engraving accuracy and colour or shade consistency can be assessed under controlled conditions before cylinders are dispatched for production use.

A key feature of the facility is its fully air-conditioned manufacturing environment. Temperature and humidity are controlled throughout the plant to maintain dimensional stability during plating and engraving operations. For precision gravure work, environmental stability is particularly important. Variations in temperature and humidity can affect cylinder dimensions and surface characteristics, potentially influencing engraving accuracy and print consistency. ATPL’s controlled production environment is intended to minimize such variations while reducing rework and maintaining tighter process tolerances.

Sustainability built into production

Environmental considerations have also been incorporated into the Silvassa operation. The plant has a dedicated wastewater treatment and zero-liquid-discharge (ZLD) system, enabling process water to be treated and recycled within the facility. This reduces the plant’s dependence on fresh water and limits the discharge of industrial wastewater. The facility also uses captive solar power, allowing solar generation to meet a significant proportion of its electricity requirements when conditions permit.

The combination of water recycling and renewable energy forms part of TCPL Packaging’s broader focus on reducing the environmental footprint of its manufacturing operations.

Targeting the external gravure market

While the Silvassa facility provides TCPL Packaging with greater control over an important part of its gravure printing supply chain, ATPL is also being positioned as a standalone cylinder manufacturer. The company estimates that the Indian gravure cylinder market accounts for around 1.5 million cylinders annually. ATPL sees opportunities particularly in specialized applications, including embossing cylinders and other requirements across multiple packaging segments.

The planned capacity expansion is expected to improve the company’s ability to serve external customers through higher production availability and shorter lead times. Consistent cylinder quality and the ability to handle specialized requirements are expected to be key differentiators as ATPL increases its presence in the market.

For TCPL Packaging, the captive manufacturing capability also offers advantages beyond production capacity. Greater control over cylinder availability can help support printing schedules, while keeping artwork and cylinder-related development activities within the company’s ecosystem provides additional security for customers’ designs. The facility can also support new product development by enabling TCPL and ATPL to work more closely on cylinder specifications and printing requirements.

Moving towards exports

The next phase of expansion is expected to give ATPL a larger role beyond TCPL Packaging’s internal requirements. With capacity expected to double by the end of 2026, the company plans to explore export opportunities and establish ATPL as a significant independent player in the gravure cylinder industry.

The strategy effectively gives TCPL Packaging a dual advantage: a more secure and controlled supply of gravure cylinders for its own operations, alongside a new business platform capable of serving external packaging and printing companies.