TCPL Packaging’s Accura Technik (ATPL) is expanding its gravure cylinder manufacturing and engraving facility at Silvassa in Gujarat, with the company targeting a doubling of capacity by December 2026 as it builds a larger presence in India’s gravure cylinder market.
The facility was commissioned in November 2025 and is strategically located close to TCPL Packaging’s operations and the established packaging and gravure printing ecosystem in western India just north of Mumbai.
“We invested approximately ₹50 crore to establish the Silvassa facility, commissioned in November 2025, strategically chosen for its proximity to TCPL Packaging’s operations, established logistics ecosystem, and skilled workforce in gravure printing and packaging. The location also offers cost efficiency and access to large gravure printers in the western region, enabling us to build credibility as a dedicated cylinder manufacturer quickly,” Saket Kanoria, managing director of TCPL Packaging, said.
Approximately 50% of current production is for TCPL itself and 50% for external customers, a mix that is expected to shift further towards third-party business as capacity expands.
“Currently, we process cylinders for both TCPL and external customers and operate at 75% utilisation. However, we are further expanding operations,” he said. “Our expansion programme will be completed before December 2026, with a target to double our capacity.”
The fully air-conditioned cylinder manufacturing and engraving facility has controlled temperature and humidity, which are particularly important for maintaining dimensional stability and precision during copper and chrome plating and engraving. “Controlled temperature and humidity are critical for precision work; they prevent chrome and copper surface warping, ensure accurate engraving depth tolerances, and extend equipment lifespan. The stability also reduces rework rates and allows us to hold tighter tolerances, translating directly to superior print quality for our customers,” Kanoria said.
The Silvassa plant has an integrated workflow covering cylinder preparation, plating, polishing, engraving, and proofing. “We operate a complete set-up from Heliograph Holding companies with advanced laser and stylus engraving systems for high-precision work, state-of-the-art copper and chrome plating lines, automated polishing systems and cylinder proofing systems. These capabilities deliver consistent quality and specifications across applications—from flexible packaging to cigarette cartons,” he said.
The manufacturing process begins with steel cylinders, which undergo cleaning, degreasing and surface preparation before copper plating. The copper surface is polished before the cylinders move to engraving. ATPL uses both electronic/stylus engraving and laser engraving technologies, while automated cutting and polishing equipment supports higher levels of process automation.
The facility also contains dedicated cylinder storage and inspection and quality-control areas for checking surface defects, engraving quality, and color or shade matching. Controlled inspection conditions allow the company to identify errors before cylinders are released for production.
Environmental management is integrated in the plant’s design. A dedicated wastewater treatment zero-liquid-discharge (ZLD) system allows process water to be recycled within the facility. “We’ve invested in a dedicated wastewater treatment zero-liquid-discharge (ZLD) plant that recycles 100% of process water back into production. These measures align with TCPL’s sustainability goals and significantly reduce our per-cylinder environmental footprint,” he added. In addition, the plant uses captive solar power, with solar generation meeting a significant portion of its electricity requirements when sunlight conditions are favorable.
The ATPL subsidiary in Silvassa is not only an in-house cylinder engraver for TCPL but also a standalone gravure cylinder supplier to the industry. Kanoria says the company sees significant potential in the external market, particularly in specialised applications. “The Indian gravure cylinder market is estimated at 15,00,000 cylinders annually. Our goal is to cater to specialised applications including embossing cylinders for multiple segments.”
As capacity increases, the company expects external sales to grow, supported by shorter lead times and the ability to serve specialised requirements. “As capacity expands, we expect external sales to grow substantially, driven by consistent quality, short lead times, and our ability to handle niche applications.”
The facility also provides TCPL with greater control over cylinder availability, artwork security, and new product development. “TCPL has already benefited greatly from this facility as ATPL offers a very reliable solution besides securing customers’ artwork and participating in new developments.”
With the ATPL expansion scheduled for completion before December 2026, it is also looking beyond the domestic market. The company intends to use the additional capacity to establish itself as a major independent supplier. “Our vision is to establish ATPL as India’s premier gravure cylinder manufacturer. We have invested in state-of-the-art technologies already and will continue to do so. With the new expansion in plan, we will be exploring export opportunities.”
The expansion of ATPL represents more than an increase in cylinder capacity for TCPL Packaging. It is part of the company’s broader vertical-integration strategy, giving it greater control over a critical component of gravure printing while creating a platform for ATPL to develop into an independent supplier to the wider packaging industry.
