Interview with Mr.P.S.Paintal , Managing Director, Zenith Worldwide
We were the first manufacturer in India to introduce PU Rollers for Paper Industry which is an ideal representation of our value to consistently deliver high-quality and innovative solutions.
Paper Desk : Could you provide information regarding the inception of Zenith Rubber’s roller manufacturing and the evolution of this journey over time?
P.S.Paintal : Zenith Rubber commenced its roller manufacturing operations approximately 50 years ago, initially focusing on printing rollers and subsequently diversifying into sectors such as paper, steel, and textiles. We take pride in being the sole manufacturer in India that produces rollers for nearly all industries, providing roller covers made from rubber, polyurethane, and composite materials.
Notably, we are currently the exclusive producer of composite rollers, and for the past three years, we held the distinction of being the only manufacturer of polyurethane rollers until the recent entry of two new competitors in the market. Regarding the challenges we have encountered, we have certainly faced numerous obstacles.
A significant challenge has been the ongoing necessity for upgrades, particularly in light of the emergence of newer, faster machinery and the demand for more advanced compounds. Nevertheless, we have effectively addressed these challenges by investing in superior equipment, skilled personnel, and technological advancements to maintain our competitive edge.
PD : What is your Mission & Vision?
PS : Our Mission is to keep delivering cutting-edge solutions of the highest quality with a customer-first mindset and to always remain at the zenith innovation in this ever-evolving industry. And the Vision is to create competitive advantage for our clients by setting a benchmark for quality and become a name synonymous to rollers across the world.
“We aim to further our efforts to become one of the top roller manufacturers in the world by offering premium products and services at best value”
PD : What types of rubber rollers do you produce for the paper industry?
PS : At Zenith Rubber, we specialize in the production of an extensive variety of rollers designed for the paper, steel, and packaging sectors. Our manufacturing capabilities allow us to create rollers that can reach lengths of up to 8 meters, diameters of 2 meters, and weights of up to 40 tons. We offer rollers with coverings made from rubber, composite materials, and polyurethane, addressing diverse industrial requirements while emphasizing durability and high performance.
PD : What is the timeframe for production and delivery, and do you provide options for customization?
PS : The production of new rollers typically requires a timeframe of approximately six to eight months, as we also manufacture the core component. In contrast, the recoating process—whether involving rubber, polyurethane, or composite materials—usually takes around three to four weeks. This duration may fluctuate based on the availability of the assembly line. If the line is accessible, we can accelerate the delivery; however, the standard delivery period from the date of order confirmation is generally four to five weeks.
PD : We heard that Zenith have recently introduced an epoxy resin composite cover within your polyurethane product range. What has been the market performance of this product to date?
PS : We have provided over 1,000 polyurethane epoxy resin composite rollers, and the feedback has been exceptionally favorable. This product was introduced three years ago, and since its launch, even our competitors have acknowledged the market’s potential. They are acquiring these machines, despite not being European manufacturers.
Additionally, there are Chinese machines entering the market, as they too recognize the significance of polyurethane. By introducing this product, we have transformed the roller industry. The introduction of polyurethane was a daring decision, particularly given that it is priced three to four times higher than conventional rubber rollers. Initially, persuading customers to embrace this new product posed a challenge; however, we have successfully overcome this hurdle, and demand continues to rise. Currently, we are selling over 1,000 units in India alone, and this number is still increasing.
PD : What unique features does your machinery possess, and how does it differentiate itself from similar
producers available in the market?
PS : We have enhanced our capabilities in rubber coverings by partnering with leading companies that have been at the forefront of its production. We have acquired their formulations to improve our offerings. In the realm of polyurethane, we employ European technology that is on par with that utilized by prominent suppliers such as Voith, Valmet, and SchäferRolls.
All our raw materials are imported from regions outside India, primarily from Europe, Australia, and the United States. We prioritize the use of high-quality raw materials to ensure the delivery of superior products. Regarding our composite rollers, which we introduced two years ago, both the raw materials and machinery are sourced from Europe. Overall, we distinguish ourselves through our skilled workforce, state-of-the-art machinery, and premium raw materials.
PD : What about the export market for your new range of rollers?
PS : Our rollers have been successfully exported to markets in Africa, Russia, and the Middle East. However, our entry into these international markets was delayed as we aimed to solidify our presence in the domestic market initially. In the realm of international trade, references play a vital role; clients tend to value the proven performance of products more than mere marketing assertions. Approximately one year ago, we commenced our export activities, and to date, we have delivered around 30 to 35 rollers, all of which are functioning effectively.
PD : What proportion of your complete product range is allocated to domestic and international markets?
PS : At present, more than 80% of our production is dedicated to the domestic market. Our primary focus has been on satisfying the domestic demand, which has limited our ability to fulfill all export requests. Additionally, the export market is highly competitive, and we currently do not have the capacity to devote the necessary time and resources to it. As part of our growth strategy, one of our objectives is to expand our facilities over the next five years, potentially adding two or three additional factories in India to better accommodate our increasing demands.
PD : What new projects and growth initiatives are you planning for your company?
PS : In terms of expansion and new projects, we manufacture roll grinders, which we have supplied to various industries, including steel and paper. Currently, we produce an average of six to seven roll grinders each year. Recently, we’ve started marketing these grinders in overseas markets, particularly in the Middle East, and on the domestic front, we’ve received three orders from Jindal.
We are also planning to establish another plant dedicated exclusively to manufacturing roll grinders by next year. Although we’ve been producing roll grinders for seven to eight years, we hadn’t highlighted this segment until recently. It’s only in the last year that we began actively marketing them, and this focus is proving to be a valuable addition to Zenith Rubber.
PD : Numerous mill owners seek assistance from global machinery manufacturers for components and equipment. Therefore, what are the discrepancies between our operations and those of international machinery manufacturers, and in what areas do we find ourselves lacking?
PS : In the realm of technology, we currently find ourselves approximately six to seven years behind manufacturers in the United States and Europe. Nevertheless, this disparity is offset by our competitive pricing. For example, a roll grinder produced by a European manufacturer is priced considerably higher than one of our own. Our domestic machinery can fulfill around 60-70% of the operational requirements needed for effective performance, in contrast to foreign equipment, enabling operators to achieve their desired results.
To illustrate, while a machine may boast 100 features, an operator typically requires only about 10 of them. By tailoring the machine to emphasize these essential features, we offer superior value for money. This scenario is akin to purchasing a premium smartphone with numerous capabilities, yet only utilizing around 40 of them. In such cases, a more economical option without the additional features may be preferable.
This is where our strength in customization becomes evident. Moreover, the cost of labor and raw materials is relatively lower in our region, further enhancing our competitive advantage. Collectively, these elements constitute our primary strengths in the marketplace. In summary, although we may trail behind international manufacturers in terms of technology, we effectively mitigate this gap through our competitive pricing and customized solutions. Our emphasis on personalization allows us to address the specific needs of our clients, ensuring they receive optimal value from our products.
PD : Could you provide us some insight into your future plans?
PS : In the coming five years, we envision our company as a leader with significant expertise in technology, machinery, and human resources. We have diligently embraced new technologies, ensuring we remain aligned with the advanced machinery being introduced in the Indian market. Our ambition is to establish ourselves as one of the foremost manufacturers of rollers made from rubber, polyurethane, and composite materials. Furthermore, we are exploring new avenues for growth. We are currently testing shoe press belt technology and are preparing to launch this innovation in the market. Additionally, we are planning to enter the field of laser engraving, with a dedicated team already in place for this initiative. Consequently, we anticipate several exciting developments ahead and are optimistic about achieving success in these endeavors.
PD : How is the Indian Paper Industry Growing?
PS : The Indian paper industry is witnessing substantial expansion, largely fueled by increasing literacy levels, the development of educational sectors, heightened demand for packaging paper resulting from economic advancement and urbanization, and an intensified emphasis on sustainable packaging alternatives. This growth persists even in the context of the digital era, positioning India as one of the fastest-growing paper markets worldwide.
“With total turnover experiencing phenomenal growth of 500% in the last five years, Zenith has emerged as a multimillion dollar conglomerate and a world leader in the rubber roller industry”
