Tulsi Paper Mills Pvt. Ltd. (TPMPL) is a leading manufacturer of high-quality duplex board and paperboard, proudly serving both national and international markets since 2013. With a cutting-edge manufacturing facility in Surat, Gujarat, TPMPL is driven by a mission to recycle waste paper, reduce environmental impact, and deliver superior paper products for the packaging industry. Our team of experts ensures every product meets strict quality benchmarks, backed by deep industry knowledge and advanced machinery.
PaperDesk : What inspired the promoters to establish Tulsi Paper Mills as a recycling-based paperboard venture, and how did sustainability shape its initial vision?
Ashokkumar Gangani : One of the promoters are in the business of trading of same products so it inspires all promoters into backward integration to manufacture the same products. The know-how of market is very well initially, and it is the USP of sustainability of recycled based paperboard venture.
PD : How did early R&D efforts contribute to developing efficient waste paper recycling methods and improving pulp quality in the initial years?
AG : As such no R&D facility but we have very good communication between our shopfloor employee, senior staff and vendors, this management style leads us to develop efficient wastepaper recycling methods which enhance through put and pulp quality.
PD : What key operational and technological challenges influenced your approach to building a state-of-the-art manufacturing facility?
AG : Initially we had site selection where government power supply is the problem, so this is the first mill in Gujarat has started the power plant first, All the plant equipment are purchased from quality vendors and assembled the entire state of the art manufacturing facility. Design in such manner that it will go up to 500 TPD production, currently we are producing 250 TPD.
PD : How does Tulsi Paper Mills ensure consistent quality and performance in duplex boards across varying GSM ranges and customer requirements?
AG : We had online quality control QCS system in paper machine, Basis weight management system to control GSM, Separate Quality and Control department with state-of-the-art laboratory to check Raw material quality and also finished product. Best in class Coating System. World class Synchro cutting system.
PD : What R&D initiatives are undertaken to enhance surface properties, coating quality, and printability of grey and white back duplex boards?
AG : To ensure best surface property we had very good balance of fiber mix in each layer of board which produce very good base board for coating. For coating we have very rich coating slurry of world class ingredients like Binders, USA mines clays, Carbonate and so on…..As mention above we have very good Quality and Control department with very good machine configuration and these all take care of surface property, coating quality and printability.
PD : How do advanced technologies like blade coating and size press systems improve product durability and packaging efficiency?
AG : We had already Blade coating and size Press system of world class manufacturer in our machine. These both system gives best smoothness, print gloss and hand feeling in our board which results less ink absorption and very good run ability of board in printing machine.
PD : How is Tulsi Paper Mills adapting to evolving global packaging demands, especially in sectors like FMCG, pharmaceuticals, and electronics?
AG : Truly speaking we are selling our products in only Indian market but our board which are applyon product packaging for many exported FMCG, Pharmaceuticals and electronics goods. So we shouldfollow all internation standard in our manufacturing process.
PD : How has your customer-centric approach helped build long-term partnerships across domestic and international markets?
AG : As this is the era of customer and we feel that we are not a product manufacture company we are service provider to our customer in terms of Quality, minimum inventories at customer end,timely deliveries by arranging good transport service.
PD : What role does R&D play in optimizing production efficiency, reducing costs, and improving turnaround time in your operations?
AG : As earlier we said that our complete involvement from bottom system to top management with marginal change leads in R&D paly in optimizing production efficiency, reducing costs, and improving turnaround time in our operations.
PD : How do you leverage technical expertise and industry experience to stay competitive in the highly dynamic paper manufacturing sector?
AG : Its key in manufacturing sector that your relationship with other plants senior persons can avail any technical achievement by that particular plant in industry will help you to sustain in competitive market.
PD : How do you view the transformation of India’s paper industry with the adoption of advanced recycling and manufacturing technologies?
AG : It is times demand and without adopting advance technical developments and changes you cannot survive long in manufacturing. In India we cannot adopt earlier Europe technological advancement due to their high cost but now a days its available because technical coloration by Asian (Chinese/Indians) and European firms.
PD : What growth opportunities do you foresee for the Indian duplex board and packaging industry in the global market?
AG : Government of Indias ban on single use plastic and awareness program will lead to increase the consumption of paper packaging, as high literacy rate also the key factor for packaging, Food process industry growing and will back by government initiative, Export promotion and tie- up/trade agreements with many countries, these all changes will create growth opportunities for the Indian duplex board and packaging industry locally and globally.
PD : How is R&D expected to shape future innovations in biodegradable materials, circular economy practices, and alternative fiber sources?
AG : As Indian government have very less programs for R&D support compared to worldwide programs related to future innovations in biodegradable materials, circular economy practices and alternative fiber sources. We industries have no such funds allocation due to very less realization compared to other sectors So R&D backed program must be initiate by government.
PD : What strategic investments in technology and capacity expansion will drive the next phase of growth for your company and the industry?
AG : We are currently investing in waste to heat recovery Boiler which generate steam and power both, also having optimization in steam consumption by adding cascade steam system in paper machine replacing conventional system.
In Pulp mill for Top Layer, we are establishing Deinking plant of Andritz make which will be ready by November 2026, it is fully DCS system, In filler layer, we are planning for good Drum pulping system. These all changes drive us to next phase of growth and capacity will increase
from 250 TPD to 350 TPD.
PD : How does Tulsi Paper Mills integrate sustainability and environmental responsibility into its core manufacturing practices?
AG : Tulsi Paper Mills integrate sustainability and environment responsibility by having ZLD approvals from day one, waste to energy setups, ESP in flue gas cleaning system also more than sufficient green belt.
PD : What R&D initiatives support waste reduction, resource conservation, and eco-friendly production methods within your operations?
AG : Waste to energy boiler is our key and it is the first AFBC BOILER IN INDIA WHICH FIRE OUR IN- HOUSE PLASTIC WASTE ALONG WITH COAL, which leads towards zero waste in terms of plastic. We are doing R&D FOR CHEMICAL SEPRATION AT ERVRY INDIVIDUAL DISHCHARGE POINT BEFORE IT MIXED IN EQUALISATION TANK IN ETP.
Eco friendly production methods like top layer water used in under layer and then Filler layer, many times we have no water left in ETP TO Feed Secondary cleaning system because of optimization in water uses.
PD : How do your practices contribute to reducing landfill waste and promoting circular economy principles in the paper industry?
AG : We are going towards zero waste generation company concept PROMOTING CIRCULAR ECONOMY by 2030. For plastic and ETP sludge waste we have new waste to energy boiler, for ash we had tie-up with brick manufacture SO FROM NON HAZARDUOUS SOLID WASTE WE HAD NO MATERIAL FOR LANDFILL, FOR HAZARDUOUS WASTE WE HAD TIEUP WITH TSDF SITE BHARUCH, IN TERMS OF WATER WE HAD ZLD.
PD : What key milestones, recognitions, or industry achievements reflect your company’s growth and credibility in the paper manufacturing sector?
AG : AS SUCH NO CERTIFICATE WE HAVE BUT GST DEPARTMENT ISSUE RECOGNITION CERTIFICATE ERVRY YEAR IT SHOWS OUR CERDIABILITY IN MARKET.
PD : What R&D-driven innovations or product developments have recently positioned your company as a leader in sustainable packaging solutions?
AG : WE ARE NOT MARKET LEADER IN PACKAGING INDUSTY BUT WE ARE WEL ORGANISED COMPANY IN MARKET.