TCPL Packaging doubles gravure cylinder capacity at Silvassa with zero-liquid-discharge, solar-powered facility

INDIA – TCPL Packaging is doubling the capacity of its gravure cylinder manufacturing facility in Silvassa, Gujarat, through its subsidiary Accura Technik, with the INR 50 crore (US$6.0 million) plant featuring zero-liquid-discharge wastewater treatment, captive solar power, and integrated laser and electronic engraving technologies.

The expansion, announced on 19 August 2026, follows the facility’s commissioning in November 2025 and is expected to be completed before December 2026, effectively doubling the plant’s existing capacity. 

The Silvassa location provides access to the packaging and printing ecosystem in western India, with logistical advantages and access to skilled manpower.

Integrated Manufacturing and Precision Control

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, allowing the plant to cater to different cylinder specifications and applications ranging from flexible packaging to cigarette cartons. 

A key feature of the facility is its fully air-conditioned manufacturing environment, with temperature and humidity controlled throughout the plant to maintain dimensional stability during plating and engraving operations. 

The plant also has dedicated areas for cylinder storage, inspection and quality control, with surface defects, engraving accuracy and colour consistency assessed under controlled conditions.

Sustainability and Capacity Expansion

The plant has a dedicated wastewater treatment and zero-liquid-discharge system, enabling process water to be treated and recycled within the facility, reducing dependence on fresh water and limiting industrial wastewater discharge. 

The facility also uses captive solar power, allowing solar generation to meet a significant proportion of its electricity requirements. 

The facility is currently operating at around 75 percent 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, with the expansion aimed not only at supporting TCPL’s growing cylinder requirements but also at developing ATPL into an independent supplier to the wider packaging market.

Market Opportunities and Export Plans

The Indian gravure cylinder market accounts for around 1.5 million cylinders annually, with ATPL seeing opportunities particularly in specialized applications including embossing cylinders and other requirements across multiple packaging segments. 

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.

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