Company Background:TCPL Packaging Ltd., (formerly known as Twenty-First Century Printers Ltd) was promoted by the Kanoria family, and began commercial production in April 1990. It is one of India's largest manufacturers of printed folding cartons, and one of the few listed packaging companies in India.
Today, TCPL Packaging Ltd. operates out of its six manufacturing units ; three in Silvassa, 180 kms from Mumbai in Western India ; two in Haridwar, 200 kms from Delhi in Northern India ; and one in Goa, 600 kms from Mumbai in Western India. All the plants are ISO 9001: 2008, ISO 22000: 2005 certified and are also compliant with BRC/IoP Global Standard-Packaging Issue 3, which is suitable for direct food contact. In addition, plants at Silvassa and Haridwar are also FSC certified & SEDEX Compliant.
TCPL is one of the largest exporters of printed cartons from India. It regularly caters to consumers in countries like UK, The Netherlands, UAE, Bangladesh etc. Exports constitute about 17% of TCPL's annual revenues.
TCPL is the country's second
largest carton manufacturer after ITC. While ITC manufactures carton for captive
consumption, TCPL biggest clients are Godfrey Philips India, Nestle India,
Colgate, Godrej, HLL, Seagram and Jagatjit Industries. TCPL prints Shells and
Hinge Lid Blanks required by cigarette manufacturing companies and Cartons,
Boxes & other packaging material for various companies in the booming
liquor, FMCG, Food & Beverages segment and others.
TCPL won several awards for excellence in printing
from Paper, Film & Foil Converters Association for cartons manufactured for
various customers. TCPL has core manufacturing business and enjoys reputation
of a reliable packaging company for supply of various types of packaging
materials to large foreign and domestic companies. It is presently
consolidating its operations and working on new product offerings.
Production
Facilities
1. The Silvassa Factory
Offset Packaging Unit: This unit houses three MAN Roland 700 offset presses all of which are six colour with inline coaters. The plant is also equipped with multiple line Bobst folder-gluers and die-cutters as well as window patching machines. Besides, the facility also has equipments for hot foil stamping, automatic film lamination and every other conceivable finishing capability. Of the three offset machines, one is equipped with interdeck UV driers capable of printing on plastic and non-absorbent substrates. The die-cutter and folder gluers are also similarly equipped to handle plastic substrates. In addition, a sheet fed gravure printing machine has also been recently commissioned, enabling the plant to print by both offset and gravure or in combination thereof.
Fluted Carton Unit: This unit set-up in March 2010 is a dedicated facility for production of E / F fluted cartons. It houses 2 lines of E/F fluting corrugation single facers, Litho Laminator, three special die cutting equipment designed for fluted cartons and specialised folder gluers from Bobst equipped for gluing/folding of fluted cartons. The plant is also equipped with a hot room for control of moisture and is fully equipped to handle sophisticated requirements of E / F fluted cartons.
2. The Haridwar Factory
TCPL Packaging is now operating two plants at Haridwar. Of the two plants, one houses the sheet fed offset machines, and the second one is a dedicated facility for corrugated cartons.
Offset Packaging Unit
Printing: Haridwar plant is equipped with two Mitsubishi LX six color sheet fed offset printing machines, one KBA 106 six color sheet fed offset printing machine equipped with in-line coaters besides a sheet-fed gravure printing machine to enable it to print offset-gravure combination jobs.
Die-cutting: Multiple number of state-of-art die cutters from Bobst with in-line stripping facility.
Folding & Glueing: Multiple lines of high speed folding and glueing facilities from Bobst equipped with crash lock bottom devices. Folding & Glueing equipment at Haridwar plant is equipped with a Code Reader Xtend Series from Baumer HHS in combination with lower glue line detection.
Window Patching / Liner Capability: Three Heiber & Schroder Window Patching machines with liner capability.
Fluted Carton Unit
This unit set-up in March 2012 is a dedicated facility with state-of-the art technology for production of E / F fluted cartons. It houses one line of E / F fluting corrugation single facer, Litho Laminator with all latest and automated features, special die cutting equipment designed for fluted cartons and specialised and renowned folder gluer equipped for gluing/folding of fluted cartons. The plant is also equipped with latest testing equipments for quality assurance and a hot room for control of moisture and is fully equipped to handle sophisticated requirements of E / F fluted cartons.
3. The Goa Factory
TCPL operates one plant at Goa. This unit set-up in July 2012 is a dedicated facility for production of E/F/N fluted cartons. It houses 2 lines of E/F/N fluting corrugation single facers, Litho Laminator, three special die cutting equipment designed for fluted cartons and specialized folder gluers from Bobst equipped for gluing E/F/N and straight line glued cartons at high speed. The plant is also equipped with a hot room (de- humidifier) for control of moisture and is fully equipped to handle sophisticated requirements of E/F/N fluted cartons.
The Prepress Centre
TCPL always put best of its efforts to exceed customer expectations. It is with this objective that TCPL has promoted a company viz. Accura Reprotech Pvt. Ltd., (ART) based out of Mumbai which is responsible for prepress and repro activities of the company. ART has been set-up to focus on areas such as structural and graphic design, use of varied raw material and suggesting to customers, different types of finishes to be incorporated in their packaging.
This centre is located in heart of Mumbai making it easy for customers to visit the centre and experiment with different possibilities. ART is equipped with Esko Graphics Suite 10 PDF enabled workflow and has all facilities under one roof geared up for designing, editing and processing of jobs. The facility is also equipped with the latest Kongsberg Sample Table for the production of printed / unprinted cartons including complete proofing facility. ART is connected to both manufacturing plants by dedicated leased lines and to customers via FTP (File transfer protocol).
1. The Silvassa Factory
TCPL Packaging is now operating three plants at Silvassa. Of the
three plants, one houses the web fed gravure machines, the second houses sheet
fed offset machines and the third is a dedicated facility for corrugated
cartons. As a result the Silvassa operations are extremely versatile allowing
TCPL to offer printing on a variety of substrates and combinations thereof, as
also capability to cater to a variety of requirements depending on the nature
of the job in terms of volume and print appearance
Gravure Packaging Unit: This exclusive gravure printing facility was set-up in January 2010 and houses three 10 colour gravure presses all with inline die cutting facilities. Of the three presses, two have been imported earlier from Komori Chambon and the third and latest one is imported from ATN Industrie, France. Two of the above three presses have the capability to rotary die cut and emboss inline besides printing in one operation. The plant is also equipped with a specialised Bobst offline die cutting and foil stamping machinery besides facilities for lamination of film to board. The printing machines are also equipped with online defect detection camera to guarantee 100% defect free supplies.
Gravure Packaging Unit: This exclusive gravure printing facility was set-up in January 2010 and houses three 10 colour gravure presses all with inline die cutting facilities. Of the three presses, two have been imported earlier from Komori Chambon and the third and latest one is imported from ATN Industrie, France. Two of the above three presses have the capability to rotary die cut and emboss inline besides printing in one operation. The plant is also equipped with a specialised Bobst offline die cutting and foil stamping machinery besides facilities for lamination of film to board. The printing machines are also equipped with online defect detection camera to guarantee 100% defect free supplies.
Offset Packaging Unit: This unit houses three MAN Roland 700 offset presses all of which are six colour with inline coaters. The plant is also equipped with multiple line Bobst folder-gluers and die-cutters as well as window patching machines. Besides, the facility also has equipments for hot foil stamping, automatic film lamination and every other conceivable finishing capability. Of the three offset machines, one is equipped with interdeck UV driers capable of printing on plastic and non-absorbent substrates. The die-cutter and folder gluers are also similarly equipped to handle plastic substrates. In addition, a sheet fed gravure printing machine has also been recently commissioned, enabling the plant to print by both offset and gravure or in combination thereof.
Fluted Carton Unit: This unit set-up in March 2010 is a dedicated facility for production of E / F fluted cartons. It houses 2 lines of E/F fluting corrugation single facers, Litho Laminator, three special die cutting equipment designed for fluted cartons and specialised folder gluers from Bobst equipped for gluing/folding of fluted cartons. The plant is also equipped with a hot room for control of moisture and is fully equipped to handle sophisticated requirements of E / F fluted cartons.
2. The Haridwar Factory
TCPL Packaging is now operating two plants at Haridwar. Of the two plants, one houses the sheet fed offset machines, and the second one is a dedicated facility for corrugated cartons.
Offset Packaging Unit
Printing: Haridwar plant is equipped with two Mitsubishi LX six color sheet fed offset printing machines, one KBA 106 six color sheet fed offset printing machine equipped with in-line coaters besides a sheet-fed gravure printing machine to enable it to print offset-gravure combination jobs.
Die-cutting: Multiple number of state-of-art die cutters from Bobst with in-line stripping facility.
Folding & Glueing: Multiple lines of high speed folding and glueing facilities from Bobst equipped with crash lock bottom devices. Folding & Glueing equipment at Haridwar plant is equipped with a Code Reader Xtend Series from Baumer HHS in combination with lower glue line detection.
Window Patching / Liner Capability: Three Heiber & Schroder Window Patching machines with liner capability.
Fluted Carton Unit
This unit set-up in March 2012 is a dedicated facility with state-of-the art technology for production of E / F fluted cartons. It houses one line of E / F fluting corrugation single facer, Litho Laminator with all latest and automated features, special die cutting equipment designed for fluted cartons and specialised and renowned folder gluer equipped for gluing/folding of fluted cartons. The plant is also equipped with latest testing equipments for quality assurance and a hot room for control of moisture and is fully equipped to handle sophisticated requirements of E / F fluted cartons.
3. The Goa Factory
TCPL operates one plant at Goa. This unit set-up in July 2012 is a dedicated facility for production of E/F/N fluted cartons. It houses 2 lines of E/F/N fluting corrugation single facers, Litho Laminator, three special die cutting equipment designed for fluted cartons and specialized folder gluers from Bobst equipped for gluing E/F/N and straight line glued cartons at high speed. The plant is also equipped with a hot room (de- humidifier) for control of moisture and is fully equipped to handle sophisticated requirements of E/F/N fluted cartons.
The Prepress Centre
TCPL always put best of its efforts to exceed customer expectations. It is with this objective that TCPL has promoted a company viz. Accura Reprotech Pvt. Ltd., (ART) based out of Mumbai which is responsible for prepress and repro activities of the company. ART has been set-up to focus on areas such as structural and graphic design, use of varied raw material and suggesting to customers, different types of finishes to be incorporated in their packaging.
This centre is located in heart of Mumbai making it easy for customers to visit the centre and experiment with different possibilities. ART is equipped with Esko Graphics Suite 10 PDF enabled workflow and has all facilities under one roof geared up for designing, editing and processing of jobs. The facility is also equipped with the latest Kongsberg Sample Table for the production of printed / unprinted cartons including complete proofing facility. ART is connected to both manufacturing plants by dedicated leased lines and to customers via FTP (File transfer protocol).
Today, TCPL Packaging operates out of its six manufacturing units: three in Silvassa, two in Haridwar, and one in Goa.
The company prints and finishes 3,600 tonnes of carton every month or 43,360 tonnes per year. Its sales have risen from 1.31 million USD at the start of the 1990s to 69 million USD today.
The new 8-color KBA Rapida 106 press with coater ordered by TCPL Packaging is equipped for printing board and film. It will be set-up for UV mixed operation allowing the firm to offer maximum flexibility in terms of in-line finishing. The press which will be raised by 450mm (17.7in) is equipped with features typical for packaging printing, such as non-stop automatic facilities at the feeder and delivery, a coating supply and cleaning system, IR/TA/UV drying systems in the delivery extension, as well as four VariDry UV interdeck dryers.
Automatic plate changers, impression cylinder, blanket and roller washing units for conventional and UV printing and EES exhaust-air cleaning system round off the press’ kit, which KBA said boosts productivity.
It is the third KBA Rapida 106 press installed by TCPL Packaging in Silvassa, where it operates three plants, and follows a 6-color model with coater installed in 2013 and a 7-color and coater version in 2014. The new KBA Rapida 106 will go live in 2015.
In addition, a KBA Rapida 106 with six printing units, coater and delivery extension mainly for handling plastic film has been in operation at the company’s plant in Haridwar for three years. Products combining the sheet-fed offset and sheet-fed gravure printing processes are also produced there.
TCPL’s Guwahati plant will convert 750 tonnes of paperboard per month The eight-acre campus with 85,000 sq/ft build-up area, which is located in the Industrial Growth Centre of Chaygaon in the outskirts of Guwahati, is spacious enough to accommodate multifold expansion and addition to the production base.
EXPECTING COMPANY COULD GROW 20% ANNULALLY NEXT 5 YEARS .THIS YEAR EXPECTING 40 EPS. STOCK COULD TOUCH 3 DIGITS IN NEXT 1 YEAR
