TECHNOLOGY PARTNERS FOR ENERGY EFFICIENCY SERVALL with its partnership with LARIO ENERGY, can provide a "Complete Drying Solution" for "Paper Manufacturing" for any grades and any types of Paper / Board Machines.
SERVALL is well known for its Casted Drying Cylinders across the Globe since 50+ years delivered over 3500+ Drying Cylinders with TUV; ASME certiďŹ cations with its excellent foundry facility. LARIO a leading global specialist in ventilation & steam system for paper industry since 1982 delivered over 450+ installations across 40 countries
LARIO ENERGY Steam & Condensate System Enclosed Hoods High Velocity Hoods for Tissue Machines Contactless Drying Systems for coating sections Heat Recovery Sheet stabilizers & Rope Less Tail Threading Systems
C•O•N•T•E•N•T•S SPECIAL FEATURE
Jal hi jeevan hai WAT E R I S L I F E !
10
Jani Sales: Strengthening its Business With New 100 TPD MG Paper Plant
40 Chadha Papers: Banking on Value Added Products
8 | www.papermart.in / August-September, 2020
44 38
Adler Paper: Turning Waste into Meaningful Resources
NEWS
66
S•P•E•C•I•A•L F•E•A•T•U•R•E
Jal hi jeevan hai WAT E R I S L I F E !
Keeping in view the long-lived value in staying ahead of the curve and being sustainable, the papermaking companies have made directed efforts paving a way for the efficient management of water usage in their facilities.
10 | www.papermart.in / August-September, 2020
S•P•E•C•I•A•L F•E•A•T•U•R•E According to the United Nations World Water Development Report 2020 titled ‘Water and Climate Change’, global water use has increased by a factor of six over the past 100 years and continues to grow steadily at a rate of about 1% per year with increasing population, economic development and shifting consumption patterns. In face of the ever-growing demand of water, the pattern of wastewater management is shifting from ‘treatment and disposal’ to ‘reuse, recycle and resource recovery.’ This trend is particularly true for the Pulp and Paper Industry, where wastewater is increasingly being seen as a potential resource and its use or recycling after it is treated — in turn fulfils corporate social r e s p o n s i b i l i t y, water stewardship and sustainable development. Water recycling practices in paper mills – a crucial parameter for overall sustainability Water usage in the pulp and paper industry is needed in almost every part of the process, whether the facility is digesting wood chips, producing fiber slurries, or washing the machinery and rollers. Due to scarcity and relatively high cost of water treatment, the pulp and paper mills around the globe have made efforts to minimize the consumption of fresh water through efficient use, increased reuse/recycling of waste
water and adoption of the state-ofthe-art technologies. In fact, the concept of recycling is going to be a long-term strategy for the Indian paper industry. The industry is practicing the ‘recycle’ concept with a greater degree of success, which has resulted in lower consumption of fresh water – as it is an invaluable resource. Mr. B. Makarand, Unit Head, ITCPSPD Unit - Bhadrachalam asserts, “Our journey of water conservation
initiative in the last two years was fruitful, we have been able to reduce 4,272 KLD of freshwater consumption, reuse 8400 KLD of back water and recycle about 4,700 KLD of treated effluent from mill ETP for process application.” Conserving freshwater and maximizing the usage of backwater With the increased concern for improved and cost effective use of available natural resources along with greater emphasis put on pollution control, the paper mills have made a
structured approach – for instance, they maximize the water usage efficiency and institute a number of steps which help them in reducing freshwater consumption to a great extent. Elucidating the progress made with regard to fresh water conservation, Mr. R.K. Bhandari, Joint Managing Director, Satia Industries Limited, affirms that “The high-water consumption has been well controlled by SIL as the initial water consumption which was 65-70 m3 per ton of paper a few years back have been brought down to almost 40 m3 and after the expansion, it will be less than 30 m3 per ton of paper.” With the purpose to conserve water and have a suitable infrastructure in place – to support water recycling, the paper mills are making significant investments than before to bring about the water treatment processes and are more vigil about the freshwater usage. Paper Mart initiated an editorial feature wherein some of the India’s leading paper mills talked about the existing practices, efforts and technologies put into use by them for managing the resource effectively, while also enhancing competitiveness. This feature provides insights on existing good practices, new technologies, for managing the resource effectively, while also enhancing competitiveness.
www.papermart.in / August-September, 2020 | 11
S•P•E•C•I•A•L F•E•A•T•U•R•E “Our journey of water conservation initiative in the last two years was fruitful, we have been able to reduce 4,272 KLD of freshwater consumption, reused 8,400 KLD of back water and recycled about 4,700 KLD of treated effluent from mill ETP for process application” ITC: A Water Positive Company Over the years, ITC has been creating rainwater harvesting capability through extensive investments in its integrated Watershed Development projects. As on March 31, 2020, these projects covering over 1.13 million acres of land have created a total rainwater harvesting potential (RWH) of close to 39 million kl -- over 3 times the net water consumed by ITC’s operations in 2019-20.
Mr. B. Makarand, Unit Head, ITC- PSPD Unit - Bhadrachalam
I
TC-PSPD has four production units- in Bhadrachalam and Bollaram in Telangana, in Kovai, Tamil Nadu and in Tribeni, West Bengal. The Company is a market leader in both virgin and highquality recycled fibre-based boards and has the total capacity of 9.2 lac TPA. ITC’s focus on being a carbonpositive, water-positive, zero-solid waste disposal organization leads it to constantly develop ways of reducing, reusing and recycling, and thereby, being an environmentally-responsible and sustainable organization. ITC’s Paperboards & Specialty Papers Business (PSPD) integrated facility at Bhadrachalam has been conferred the GreenCo Platinum+ rating by Confederation of Indian Industry (CII) Green Business Centre, as part of the Green Company rating system. It is the only facility in the pulp & paper sector and the second company overall in the country to have received this prestigious rating.
Water Scenario: Bhadrachalam Unit ITC PSPD unit in Bhadrachalam draws water from river Godavari, which is a perennial river. Out of the water intake for consumption, the treated effluent flows back to river. A significant portion of the treated water is released for irrigation purposes, which is an important source of water supply for farmers. ITC also developing biodiversity park in association with Telangana government by using treated effluent water. Although the Godavari is a perennial river, it is reported to be short of water supply for about three months from March to May of the dry-season. Thus, as part of our water
12 | www.papermart.in / August-September, 2020
management and conservation, we have decided to work extensively on water harvesting structures like check dams, form ponds etc. (beyond the fence or beyond the premises of our production unit), resulting in farmers not dependent on river for their agricultural activities. In addition, we ensure that no ground water is extracted for process.
S•P•E•C•I•A•L F•E•A•T•U•R•E
www.papermart.in / August-September, 2020 | 13
S•P•E•C•I•A•L F•E•A•T•U•R•E Approach and Methodology
Case Study 1 (Recycle)
We have formed a structured approach and methodology to maintain water usage efficiency by ensuring that we reduce water consumption by 5%, maximize reuse in process and increase the recycling of treated effluent. Further, we work towards enhancing the capability of employees so as to equip them with the relevant knowledge, we are always on the lookout to adopt innovative waterefficient technologies, and we give diligent attention to water conservation beyond the boundaries too.
Power Plant: The steam coming out from turbines are condensed in a tube and shell type surface condenser. The Cooling towers are used to reduce the temperature of outlet hot water which is re-circulated again in the system.
Senior Management Commitment A strong commitment and initiative towards water sustainability has been demonstrated by ITC’s senior management through various measures: • Allocating Resources: Providing the required resources in terms of CAPEX, manpower and other infrastructure. • Setting Goals Setting: Benchmarking and setting the targets. • Forming Team: Forming and empowering the cross functional team for water conservation activities. • Progressive Reviews: Periodical reviews and guidance for improvement. • Celebrations: Rewarding, recognizing and celebrating the achievements.
Case Study 3 (New Board Machine): Selecting and Adopting Water Efficient Technologies at Design Stage 1.
The condensers are provided with online cleaning system to avoid the deposits. Hence, it was tried to use the treated effluent for makeup of cooling tower after passing through filtration and softening plant. We have been able to save 1500 KL/day (Horizontal deployable) through this methodology.
Case Study 2 (Reduce): Paper Machines-Wire Lubricating Showers A paper machine requires around 2300 CUM water per day for wetting and lubricating the forming wire. This water is sprayed evenly through showers. Now, the water requirement to lubricate evenly the forming wire has been optimized with the latest “Diamond Tip shower nozzles”. The nozzle size was reduced from 1 to 0.7 mm diameter with self-cleaning arrangement without compromising on quality. With this modification, we have been able to lower the consumption of water by 825 kilo liters per day, with horizontal deployment across the units.
Employee Involvement and Capacity Building
As water ring vacuum pumps are used on conventional paper machines, it requires huge amount of fresh water. Our project team came across the latest technology of “Turbo air blowers” which has been introduced recently and operates without sealing water. Thus, ITC adopted this technology for our new board machine, although it had a higher capital cost.
2. ITC PSPD unit in Bhadrachalam is India’s first BCTMP plant. The state-of-the-art BCTMP plant was designed especially for low water requirement and liquid discharge to ETP. The spent liquor coming out of the process is concentrated in evaporators along with the black liquor of existing ECF pulping. This results in low discharge to ETP and hence lower make-up in the system.
ITC’s 3-fold Approach to Water Stewardship We have created a 3-fold approach to water stewardship, which are: •
Integrated watershed development across 16 Indian states covering 1 million acres.
•
Enhancing water use efficiency in agriculture through demand side management.
•
Maximizing water use efficiency
The total annual spend of ITC’s on water conservation is around INR 6.9 crore.
Within our approach of water conservation, we ensure that we are efficiently using the resource as by making sure that there is a continuous monitoring of water use efficiency, assessment and mitigation of water related risks at local watershed level, and grassroot capacity-building for efficient water usage in agriculture. In addition, we ensure to maintain sustainability of agriculture through integrated water shed development, conduct water security studies and hydro-geological assessments of all operational units, create rain water
14 | www.papermart.in / August-September, 2020
Leading Supplier of Complete Paper Machine, S•P•E•C•I•A•L F•E•A•T•U•R•E Equipment and Application Solutions
180+ Successfully Supply & Installations of Paper Mills & it’s Equipment in Asian & African Countries
Engineers Pvt. Ltd.
N.K.R. Engineers Pvt. Ltd. was founded in the year 1997. N.K.R. Engineers Pvt Ltd. is manufacturer and exporter of Large and Medium Recycle Paper Mill Machinery. An ISO 9001:2015 Cer fied Company Specializa on in Design & Development.
PLANT & FACILITY Ÿ Plant Area - 100000 Sq. Feet Ÿ Build Area - 80000 Sq. Feet Ÿ Lathe Machines Ÿ TOS Make CNC Boring Machine Ÿ TOS Make Automa c VTL Machine Ÿ CNC Plasma Cu
ng Machine Ÿ Automa c Plano Miller Machine Ÿ Hydraulic Press Machine Ÿ Bending Machine etc....
N.K.R. ENGINEERS PVT. LTD. Mfg.: Paper Mill Machinery ISO 9001: 2015 CERTIFIED COMPANY www.nkrengineer.com
Corp. Ofce & Works (Heavy Fabrication & Assembly Shop) "Devashray" Near Express Highway, Opp.: Shreenand City, New Maninagar Road, Vatva, Ahmedabad· 382 445, Gujarat, INDIA Phone: 079 2584 0141 / 42 I +91 92272 28909 E-mail: nkr_eng@yahoo.com | Web Site : www.nkrengineer.com
Regd. Ofce & Works (Rolls Manufacturing Facility) 3,4,5 - Jay Khodiyar Industrial Estate, Near Subhash Estate, CTM - Ramol Road, Amraiwadi, Ahmedabad - 380026
www.papermart.in / August-September, 2020 | 15
S•P•E•C•I•A•L F•E•A•T•U•R•E harvesting potential within and outside company premises and most importantly, we carry out the recycling/ reusing of all treated effluents.
Case Study 1: Beyond the Fence • • • •
Water Harvesting structures developed: 1134 Bio-diversity plots: 66 Water Storage Capacity – 4.5 lakh CUM Beneficiaries – 16,434
Achievements In the last two years, we have been able to reduce 4,272 KLD of freshwater consumption, reuse 8400 KLD of back water and recycle about 4,700 KLD of treated effluent from mill ETP for process application.
Achievements: Water Usage Efficiency Trends
Natural Resource Management in Bhadrachalam Factory Catchment area
IMPACT Intervention
UoM
Bhaskar Iravendi Nagar
Reddy palem
Total
Farm Pond
No
17
55
35
107
Area Treatment
No
237
57
89
383
CuM
3468
11220
7140
21828
No
124
80
63
267
Water Storage Capacity Beneficiary Covered
Case Study 2: Beyond the Fence – To Educate the Farmers about Water-Efficient Means in Irrigation Water is a critical input for agricultural production and the agriculture sector accounts for 80% of total water withdrawals and consumption, out of which 60% is consumed by paddy alone. Traditionally, the flooding method of irrigation is used for growing paddy with 2-3 centimeters of water. This practice of irrigation results in large scale water consumption with lower water use efficiency. There are many methods of paddy cultivation but the SRI (System of Rice Intensification) method totally deviates from the traditional way of cultivating irrigated paddy and hence, it has different water saving capabilities. The method appears to be the most efficient method of paddy cultivation with water savings reaching up to 40- 50% when compared to traditional method of
paddy cultivation. Last year, we have presented 5 demos in the murreru catchment area to mobilize the farmers towards water use efficiency; however, we are planning to scale up these demos to 60. As there is a compelling need to address the water security issue, we want to promote water use efficiency methods and educate the people in the community about various ways to conserve water. Awards & Certifications ITC PSPD’s Unit Kovai is first site in India and first Paper Mill in the world to achieve platinum rating, the highest rating under the Alliance for Water Stewardship standards. The company has also received National Award for Excellence in Water Management
16 | www.papermart.in / August-September, 2020
2019. It was awarded with Telangana State Energy Conservation Awards 2018 and TSREDCO Energy Conservation Award - 2019. ITC PSPD Bhadrachalam unit was conferred with IPMA Environment Award 2017-18 and CII -National Water Conservation Award – 2019 Challenges and ITC’s Action Plans Within Fence: There are some pertinent challenges with regard to water usage that we have to consider – there has been a continuous decline of ground water and drying of rivers which thus results in the regulatory limits on water withdrawal for businesses and the deteriorating water quality entails additional treatment expenses. To address these challenges, ITC’s
S•P•E•C•I•A•L F•E•A•T•U•R•E Action Plans are to - continuous monitor water use efficiency, focus on Reduce – Reuse – Recycle methodology, and continued investment on rain water harvesting potential. Also, we plan to conduct water security studies and hydrological assessments for operating units located in high water stressed areas.
external stake holders for assessment and mitigation of water related risks at local watershed level.
Beyond fence: The key challenge in the area of water conservation beyond our fence/premises is, as water is a crucial input for agricultural supply chain as well as production, business operations may get affected due to potential disruption in water availability.
•
Increased operation problems due to change in water quality: Accumulation of various organic and inorganic components.
•
Corrosion problems: Increased levels of calcium, chlorides, sulphates and suspended matter.
•
Adverse impact on the product quality: Lower retention and drainage of the additives.
•
Increased levels of microbial population (slime): Rise in temperature by water recyclingaffecting the runnability of paper machines.
Thus, ITC’s Action Plans to solve this challenge is by ensuring sustainability of agriculture through water shed development, soil and moisture conservation projects, aquifer recharge particularly in areas where ITC sources its raw materials. Moreover, we also give attention to engagement with
Paper Industry Specific Challenges There are some major limitations for recycling/re-use of back waters in Indian mills:
Some of the other challenges are — Recycling of treated effluent within the process is limited by the TDS limit of effluent discharge (2100 mg/l). The technology on TDS reduction is still commercially not viable and the business can be at risk due to no alternate source of water (Use of ground water is not allowed for industries). There are restrictions on water drawl during summer have impacted production in some units. In spite of these challenges, there are opportunities that we can rely on - Opportunity for cross industry learnings of best practices, treated effluent use for agriculture, as it has high nutrients. Moreover, the support from industry experts like Valmet and Andritz has helped us with reliable and efficient water audits. There is a huge opportunity beyond the fence, check dams, ponds, rain water harvesting etc. ITC-PSPD also believes in continuous improvement with employee involvement through innovative ideas and kaizens generation for improving water-use efficiency.
Manufacturer of : Complete Paper Machine from conveyor to Rewinder • Duplex • Multi Layer Kraft • Kraft • Newsprint
D.S. Pulp & Paper Machinery Pvt. Ltd. D.S. Engineers Mfg.: Paper, Pulp & Cement Plant
Works & office : Plot No. 5314, Phase IV, Ramol Cross Road, G.I.D.C. Vatva, Vatva, Ahmedabad - 382445. (Rajesh Desai) +91 9825042710, 9227225579 E-mail : dspl@ymail.com / dsengineers_raj@yahoo.com www.papermillmachineryindia.com | www.papermillindia.com
www.papermart.in / August-September, 2020 | 17
S•P•E•C•I•A•L F•E•A•T•U•R•E “The average daily water consumption in 2015-16 was 76,348 m3, which has been significantly reduced to 53,392 m3 in 2019-20. Thus, there has been a 30% reduction in the overall consumption of water.” of time to control pollution and to maintain a consistent improvement in environment performance: •
Adoption of Cleaner Technologies
•
Implementation of various inplant measures
•
Reduce & Recycle the waste
West Coast Paper Mill’s advanced super batch cooking provides about 50% reduction in steam consumption, reduction in non-condensable gases (NCG) due to cold blow and reduction in odors. The two stage Oxygen Delignification process results in reduction of bleached chemicals, reduction in BOD, COD and color of effluent.
Environment Friendly Technology Adoption
Mr. B H Rathi, President, (Technical), West Coast Paper Mills Ltd. Started in 1955, West Coast Paper Mills is one of the oldest and the largest producers of paper in India. It produces various grades of writing & printing, cup stock, Industrial grades and other varieties of paper. The ‘wood to paper’ process mastery and product research have enabled our mill to produce wide portfolio of wood-free papers and boards of highest quality. The Company is self-sustained in power front with co–generation capacity of 74.8 MW.
Water Sustainability & Environment Preservation WCPM has taken significant steps in reducing water consumption by adopting 3R principle i.e. Reduce, Recycle & Reuse. The Company has adopted cleaner production technology from time to time for environment preservation, water consumption and effluent discharge reduction. We have a strong focus towards improving the Environment Performance continuously.
In 2009, a state-of-the-art 725 TPD pulp mill supplied by Metso, Sweden, replacing the old pulp mill with eco-friendly Super Batch Cooking and Elemental Chlorine Free (ECF) Bleaching process. In the same year, a state-of-the-art new paper machine with a capacity of 1,35,000 TPA from Voith, Germany has been installed, which has greatly helped us reduce our energy and water footprint. In addition, we have adopted various new technologies in chemical recovery process and for paper machines to improve the environmental footprint and enhance the quality of pulp and paper. These developments have helped in a significant reduction in BOD, COD, colour and water consumption besides being energyefficient processes.
Environment Friendly Cooking
In fact, there are a number of initiatives that we have undertaken over a period
18 | www.papermart.in / August-September, 2020
Elemental Chlorine Free Bleaching WCPM has achieved complete elimination of elemental Chlorine for bleaching. With ECF bleaching sequence, DCS controlled operations and Online Kappa analyzer installed, the mill successfully controlled the chemical dosing resulting in reduction in Effluent load and also achieved reduction in AOX. Measures Taken for Reduction in Fresh Water Consumption: WCPM has instituted a number of measures at the level of production which helps in reducing the net consumption of freshwater. For instance, it installed state-of-theart 5th generation (New TRPE Press for Pulp Washing) Pulp Wash Press from Valmet along with Wash Presses for bleaching stages. This helped in improving washing efficiency of unbleached pulp thereby reducing carryover of chemicals and in turn resulting in reduction of BOD, COD and color of effluent. Moreover, all of the 7-press hydraulic cooling water at pulp washing and
KROFTA
NEW MEGACELL
S•P•E•C•I•A•L F•E•A•T•U•R•E
Krofta introduces State of the Art Technology: NEW DAF especially designed for Paper Industry. A unique technique, far enhanced compared to circular machines. MEGACELL PRODUCT RANGE:
SALIENT BENEFITS:
Ÿ 50-70% savings* in Civil Cost
Model Number
Maximum Flow(m³/h)
Power (kW)
Megacell-5
50
0.37
Ÿ Higher capacity Product at Low
Megacell-10
100
0.37
Foot Print (Required lessor land space)
Megacell-15
150
1.1
Megacell-20
200
1.5
Ÿ Much Lower running Power cost
Megacell-25
250
1.5
in comparison to Present DAF Technology
Megacell-30
300
1.5
Ÿ Excellent Output performance Ÿ Cheaper installation cost* Ÿ A very compact unit
Megacell-35
350
1.5
Megacell-50
500
1.5
Megacell-65
650
1.5
Megacell-75
750
1.5
Megacell-100
1000
3.0
compared to Sedicell
*As per Krofta Terms and Conditions.
Krofta Engineering Limited Durga Bhawan, A-68, FIEE Complex, Okhla Industrial Area Phase-II, New Delhi – 110020. www.papermart.in / August-September, 2020 | 19 EPBX : +91-11-4724 2500 E-mail :krofta@kroftaengineering.com Web : www.kroftaengineering.com
S•P•E•C•I•A•L F•E•A•T•U•R•E
bleaching section gets collected and it is reused back in system. Also, the white water from Paper Machine No. 4 is collected and reused in pulp mill for medium consistency of pulp dilution in the storage tower. The save-all water from Paper Machine 3 is reused in the pulp mill. The ID Fan (Recovery Boiler No. 2) fluid coupling oil cooling water has been connected to the sealing water pump suction line, so as to replace the sealing make up water with used water. At Recovery Boiler No. 1, we have made a system to ensure the collection and recirculation of pump sealing water.
•
Water clarifier blow down rate has been reduced from 40 m3/hr to 20 m3/hr.
•
Replacement of underground water pipe line to overhead pipe from Filter House to Jack well header to arrest the leakage and avoid wastage of water. Moreover, the water header at Filter House has also been replaced from underground to overhead to curb the leakage or wastage of water.
•
•
PM V excess white water supply to Pulp Mill existing water conservation system to further reduce water consumption by providing LT to water collection pit and level control valve to strengthen the makeup water line. Pulp Mill hydraulic cooling water is being pumped to the Water Reservoir.
Rotary Lime Kiln (RLK) 1 & 2 Vacuum pump sealing water, gland cooling water, and RLK-2 jet condenser water are firstly collected in a pit, cooled in cooling tower and then, they are used for recirculation. The reduction of pumps sealing water, makeup water consumption for Falling Film Evaporator (FFE) -I water conservation system is made possible by diverting RLK-I idler cooling water to water conservation pit and reused . Sealing water from FFE-II vacuum pump is recycled to utilize it again in the process.
In addition, WCPM has implemented various in-plant steps to reduce the net consumption of fresh water and form a system to re-use and recycle the water in a number of ways, such as:
With respect to reducing the overall consumption of water, the Company has formed a structured approach by undertaking these following means of action: •
Conservation of fresh water by utilizing Evaporator condensate.
•
Strengthening/modification of FFE-I existing water conservation system by installing a new 5 m3 capacity tank on ground floor that provides Level Transmitter and Level Control Valve to the tank to avoid wastage of water.
•
Jewel filter back water is reused in process.
•
Turbo Generator-2 cooling water underground line leakage has been arrested.
•
White water is used in PM-5 press pit instead of fresh water.
•
White water tank makeup water line is provided with control value interlinked with level transmitter to arrest the overflow of tank.
•
In the PM-6 press pit, white water is reused in process.
•
The water conservation tank of PM-3 has water diverted to Filler House reservoir.
•
PM-5 white water is clarified in Disc Filter and filtrate is used for PM-4 & PM-5 vacuum Pumps.
•
The back water from PM-1 is
20 | www.papermart.in / August-September, 2020
filtered and reused in vacuum pumps. •
Hot water tank overflow diverted to Filter House
is
Flue Gas CO2 Sequestering: PCC Plant WCPM has installed Precipitated Calcium Carbonate (PCC) manufacturing plant to use PCC as a filler material in paper manufacturing in place of conventional clay/soapstone. The PCC is produced by using CO2 from flue gases emanating from Rotary Lime Kiln, thereby reducing CO2 emission and reduction in air pollution. Recycle of waste lime sludge in rotary lime kiln: •
Recycling of waste lime sludge in rotary lime kiln to produce lime required for process resulted reduction in solid waste discharge
•
Non condensable gas is being used for burning
Improvements Achieved Due to continuous and untiring efforts, WCPM has been able to achieve significant progress with regard to water management by following a thorough and structured plan of action to reduce the usage of water by adopting best available technology for water and energy conservation. This has helped us to reduce environmental footprints of our operations.
World Leader in Treatment of Effluents from Recycle Paper Mill (Kraft/OCC)
Paques Expertise in Paper Industry
Over 1500 References Worldwide
Closed Loop Technology - ETP with 100% ZLD Ÿ Excellent biomass retention (2-stage
separators) Advanced Granular Based Anaerobic Industrial Ef uent Treatment
Ÿ High biomass level in reactor: high COD
capacity (VLR) Ÿ Robust, proven influent distribution
system designed to also extract biomass from the reactor
Granular Biomass Harvested Healthy Source Of Revenue
Ÿ No clogging issues and CIP of all internals
is possible Ÿ Closed reactor, no odour and no vent air
needed Ÿ Odour Less Certificate to our client &
Closed Loop /Zero Liquid Discharge
excellent paper quality Ÿ Smart reactor design and automated
control
CERTIFIED ZERO ODOUR EXCELLENT PAPER QUALITY
No RO required
No Evaporation
Paques India Manufacturing Facility: 980, BADAM ROAD, SRICITY, CHENGAMBAKKAM VILL., CHITTOOR, ANDHRA PRADESH, 517588
www.papermart.in / August-September, 2020 | 21 For more information, email us at: info.in@paquesglobal.com
revitalizing resources
S•P•E•C•I•A•L F•E•A•T•U•R•E
S•P•E•C•I•A•L F•E•A•T•U•R•E “We, at Trident, have a substantial budget dedicated to water recovery and treatment. With the support of our state-of-the-art technology and dedicated R&D teams, we ensure that there is no compromise in restoring this global resource.” put into a company’s water treatment infrastructure? RG: Generally, the cost of the water treatment in a paper mill depends upon the characterization of the input load parameters - primarily consisting of total suspended solids and biological oxygen demand.
Mr. Rajinder Gupta, Founder and Chairman, Trident Group
Paper Mart: How do you implement the water treatment process to facilitate the recycling of water and what are your different wastewater treatment strategies? Rajinder Gupta: Nature comes first — and for nature to keep thriving, we, at Trident, are committed with our extensive eco-friendly initiatives. We follow environment-conscious manufacturing practices - recycling water, zero liquid discharge and usage of non-toxic chemicals and dyes. With continuous improvement, our paper business is operating with much lesser water consumption than the benchmark set by the Central Authorities for the Pulp & Paper Industries.
We, at Trident, have a substantial budget dedicated to water recovery and treatment. With the support of our state-of-the-art technology and dedicated R&D teams, we ensure that there is no compromise in restoring this global resource. Our paper manufacturing set-up comprises services like central water reservoirs, water treatment plants, primary sludge management system, biological degradation process and anaerobic digestion to name a few. PM: Could you highlight the pivotal technologies and measures undertaken to minimize the consumption and reduce & treat large wastewater discharge? RG: Trident Group is a collaboration of many hearts reaching out to protect and preserve our environment. Embracing sustainability as a core business vertical, we have adopted different technologies to reduce the consumption as well as the pollution load. To cite a few, the adoption of
We made this possible with the implementation of smart processes like disc filtration technology and 100% recycling of water during our washing stage of raw material. We also follow multiple wastewater treatment strategies that include primary and secondary treatment of effluent along with the anaerobic digestion of the washing effluent. PM: What kind of investment has been
22 | www.papermart.in / August-September, 2020
oxygen delignification process in the bleaching sequence largely reduces the load from the paper mill through wastewater discharge. Moreover, our move to use elemental chlorine-free bleaching is also helping in reducing the discharge of organic halides. PM: Could you tell us about the recent developments taken place in your plant with regard to water management and treatment? What path-breaking steps have you taken to minimize your environmental impact and make your mill environmental-friendly? RG: The company has completed different projects to minimize the environmental impact at its manufacturing facilities. We believe that conservation of water is the way to sustainable development. For this, we have undertaken multiple initiatives such as •
Installation of filters
advanced disc
•
Installation of clarifier in the washing stage for the recycling of wastewater
•
Utilization of secondary condensate generated from recovery plant in the pulp mill
•
Utilization of paper machine backwater during pulp washing
S•P•E•C•I•A•L F•E•A•T•U•R•E
iTABLE
TM
Intelligent design creates
intelligent investment!
Over 160 installations speak for themselves! The iTABLE® is the first fully adjustable sheet forming zone for Fourdrinier machines – ideal for papermakers with a broad product portfolio. It enables precise control of dewatering and fibre suspension activity. Starting from the headbox all the way to the end of the forming zone, where fibre mobility ends. The iTABLE® increases dewatering capacity, improves paper properties & minimises raw material, energy and chemical consumption.
Your benefits
Energy & Performance
Increased production through increased dewatering capacity and machine speed.
Fabric Guides & Tensioners
Reduced basis weight with identical or improved paper properties.
Special Products
Dewatering Elements
Doctors & Showers
Improved formation, strength and surface properties.
Engineered Consumables
Reduced costs for raw materials and chemicals with the same paper properties.
Technological Services
Reduced energy demand (electricity, steam). Reproducibility, giving you increased homogeneity across the entire portfolio.
For further Information:
Engineering I Machines I Environment
Omicron Paptech LLP E-Mail: customersupport@omicronpaptech.com Phone: +91 9967037931 www.papermart.in / August-September, 2020 | 23
S•P•E•C•I•A•L F•E•A•T•U•R•E “SIL proposes to install UF-RO System for recycling of 3000 m3 of treated effluent initially to further reduce the freshwater consumption and we are exploring different technologies for their technical and commercial viability.” in the boiler, thus, reducing the fuel consumption and also reducing the carbon emission. This effluent is treated in UASBBased Bio Reactors followed by HRSCC, first stage Aeration with Jet Aeration system, followed by MBBR technology and then, it is finally sent to second stage combined aeration process. •
Mr. R.K. Bhandari, Joint Managing Director, Satia Industries Limited Paper Mart: How do you implement the water treatment process to facilitate the recycling of water and what are your different wastewater treatment strategies? R. K. Bhandari: Paper industry is one of the most water-intensive industries and both the Government as well as the industry are well aware of their responsibility to the society to use this rare natural resource to its optimum level. Ours being an integrated wood and agro pulp and papermaking plant; we have three types of effluent streams, i.e., Black liquor, Wheat Straw Wetwash, and Bleached Pulp Wash effluent. •
•
Black liquor, which is regarded as the highest pollutant effluent in the paper industry, is completely burned in specially designed Chemical Recovery Boiler and the smelt is used to produce value added product - Sodium hydroxide which is recycled for the cooking of Raw Materials. The raw material washing effluent is also used for recovery of the energy in terms of methane (Biogas) which is used for burning
Bleached pulp mill wash effluent is treated in conventional two stage activated sludge process to achieve the prescribed norms of SPCB in final discharge.
•
The foul condensate generated from evaporation of black liquor is utilized for the washing of unbleached pulp at BSW No. 4.
•
Changes in size of spray nozzle diameter in pulp mill and paper machine: Lesser diameter and high pressure reduces freshwater consumption.
•
Chlorine dioxide, alkali extraction & peroxide stage generated filtrate is used for dilution in same stage before washing.
Power Plant:
Final treated effluent is discharged onto the plantation area where approximately 600 acres of eucalyptus plantation is developed to consume the total quantity.
•
Water Conservation
Paper Machine: Utilization of backwater to recirculate, reuse and replace of freshwater:
The water conservation is an ongoing process at SIL and a number of water conservation schemes have been adopted to save water at the process level. As a result of these efforts, SIL has achieved water consumption of 35-40 m3 per ton of finished paper and after expansion; the target is to achieve water consumption below 30 m3 per ton of Paper. The lowering of the consumption has been achieved by taking the following steps:
•
The generated back water from paper machine is used for pulp dilution to make thick stock to thin stock, (TSS level of water is 1500-2000 ppm)
•
The machine back water is pumped into save-all for fiber recovery and clear water is being used in pulp dilution (TSS level of water 150-175 ppm)
•
The industry has already installed two disc filters for the treatment of excess back water to reuse in pulp mill for dilution, pulp washing and further treatment in micro drum filter (TSS level of water is 150-175 ppm).
•
This disc filter will give four types of outputs like — Recovered fibre, cloudy water, clear water and super clear water
•
Super clear water from disc filter is treated here to give less than 5 ppm TSS, thus, it replaces freshwater in low pressure showers at paper machine, pulp mill washers, and chemical preparation. (TSS level of water is 5-10 ppm)
Pulp Mill: •
TRP (Twin Roll Press): Pulp consistency increases from normal 10-12% achieved in unbleached washer to 30% which reduces pollution load in bleach effluent and increases total solids as well.
24 | www.papermart.in / August-September, 2020
Condensate from paper machine is re-circulated back over 90% to the boiler to replace freshwater consumption for steam generation.
S•P•E•C•I•A•L F•E•A•T•U•R•E
www.papermart.in / August-September, 2020 | 25
S•P•E•C•I•A•L F•E•A•T•U•R•E Particulars
Output TSS (ppm)
Utilization of Back Water
From Paper Machine (Back water)
1500-2000
For Pulp dilution from Thick stock to Thin stock and excess back water sent to Disc Filters and Marx save All to reduce further TSS level.
Marx Save All Recovery Fiber of disc filter
150-200
Used for pulp dilution from HC pulp to LC pulp
3000-4000
To replace pulp in stock preparation
From Disk Filter (Cloudy Water)
300-400
Used inlet to disc filter as sweetener
From Disk Filter (Clear Water)
150-175
Used for pulp dilution from HC pulp to LC pulp
From Disk Filter (Super Clear Water)
60-80
Used for Pulp Washing and excess water to Micro drum filter to reduce further TSS level
5-10
Used for filler dilution, Decker showers and low-pressure showers at wire part of Paper Machine
From Micro Drum Filter
PM: What kind of investment has been put into the company’s water treatment infrastructure? RKB: Water consumption after expansion — SIL has ambitious target to improve efficiency of the water treatment to further reduce water consumption below 30 m3/ton of paper by effecting recirculation wherever possible as explained in following steps:
are working out the recurring cost on account of power, membrane replacement and how to handle the heavily loaded reject.The following modifications has been brought in ETP to reduce pollution load and improve the treatment efficacy •
The industry has commissioned a new Clarifier in the wet washing plant to reduce organic load in to Bio Methanation plant at a cost of
Particulars
KLD
Total process water requirement
32235
Actual freshwater requirement
21115
Recirculation from cooling tower
400
Recirculation - 1.24 %
Recirculation from R.O. rejects
1120
Recirculation - 3.47%
Recirculation from micro filters
7200
Recirculation - 22.33%
Recirculation with tertiary treatment
2400
Recirculation - 7.44%
Total recirculation from system
11120
Total Recirculation 34.5%
Final discharge to plantation
18025
SIL proposes to install UF-RO System for recycling of 3000 m3 of treated effluent initially to further reduce the freshwater consumption and we are exploring different technologies for their technical and commercial viability. The tentative cost of this plant will be INR 4 crore and we
Remarks
INR 1.5 crore. The TSS load has been reduced by 2600 ppm to 2000 ppm (Approx. 25%). •
Increasing hydraulic load of COD/ BOD in both streams to control the outlet of Biogas Plant- COD/ BOD, the industry will introduce one more High Rate Solid Contact
26 | www.papermart.in / August-September, 2020
Clarifier (HRSCC) after anaerobic treatment at a cost of INR 0.5 crore. •
The industry has introduced primary aeration at a cost of INR 0.75 crore after anaerobic to reduce COD/BOD load on secondary effluent treatment plant.
•
The industry has introduced primary aeration at a cost of INR 0.6 crore after anaerobic followed by MBBR technology to reduce COD/BOD load on secondary effluent treatment plant.
•
MBBR and all aeration tanks are equipped with Surface Jet aerators at a cost of INR 1.0 crore to increase standard oxygen transfer efficiency.
•
Addition of pure oxygen injection system through Jet aerators in aeration tank for better organic reduction and it will increase SOT efficiencies.
S•P•E•C•I•A•L F•E•A•T•U•R•E
www.papermart.in / August-September, 2020 | 27
S•P•E•C•I•A•L F•E•A•T•U•R•E
PM: Could you highlight the pivotal technologies and measures undertaken to minimize the consumption and reduce & treat large wastewater discharge? RKB: The high-water consumption has been well controlled by SIL as the initial water consumption which was 65-70 m3 per ton of paper a few years back have been brought down to almost 40 m3 and after the expansion, it will be less than 30 m3 per ton of paper. We have consistently been on the path where we’ve been making efforts in the direction of lowering the water consumption to make it one of the lowest in the industry. We have explained the total pollution load generated in different streams and the technology used for handling that. SIL always keeps in touch with the leaders in this field to further improve the techno-commercial aspect of these technologies. We were the first in India to have Anaerobic treatment of black liquor in 1995 when there was no such technology to handle wheat straw black liquor because of silica issues and the low scale of production. We had put up our Chemical recovery plant in 2006 which has been upgraded three times till now and a bigger soda recovery boiler was installed when we had increased our agro/wood pulping capacity.
RKB: As we have already mentioned the steps taken for water management and treatment; now, we shall explain the steps we have taken to manage the environmental impact with respect to air pollution. All our boilers’ (Power boiler 50 + 90TPH and recovery boiler 80TPH steam generation capacity) emissions are controlled by providing four field electrostatic precipitators (ESP) at a cost of INR 20 crore with a target to achieve particulate emissions below 30 ppm whereas SPCB/CPCB standards are less than 150 ppm. The values which we’re achieving in particulate emissions are 80% less than standards. SIL uses only rice husk in its existing boilers for making steam and no fossil fuel is burnt. We are starting a new boiler in December 2020 which shall
PM: Could you tell us about the recent developments taken place in your plant with regards to water management and treatment? What path-breaking steps have you taken to minimize your environmental impact and make your mill environmental-friendly?
28 | www.papermart.in / August-September, 2020
use all kinds of biomass, especially the rice straw burnt by farmers in the fields, that is, the most aggravating source of air pollution. We are planning to further reduce our CO2 emissions by using the stack carbon dioxide in our proposed PCC plant which is under construction. SIL regularly keeps a watch on its carbon footprints by getting GHG emissions study done by an independent agency based on ISO 14064 guidelines and then, we analyze where best we can work to reduce it. The current focus is to use minimum possible Grid electricity, reduction in the use of Furnace oil in Recovery boiler and effective management of 600 acres of Eucalyptus plantation for maximum possible sequestration.
S•P•E•C•I•A•L F•E•A•T•U•R•E
KROFTA ENGINEERING LIMITED NEW Triple Wire Belt Filter Press (Gravity Table + Belt Filter Press)
Krofta introduces newer enhanced capacity Belt Filter Press. A new innovative unique technique, which will improve overall efficiency for sludge dewatering SALIENT BENEFITS: Ÿ First in the Country : Launched by Krofta : Triple Wire Belt Filter Press (Gravity Table + Belt Filter Press) Ÿ To enable handling of Higher throughput Ÿ Ability to handle Higher Solids per day Ÿ More Space for Squeezing the sludge in wet zone Ÿ Evenly spread of Sludge helps in more dewatering & better drainage Ÿ Compact structure and modular design Ÿ Flocculator as inbuilt supply for better dewatering MODELS AND TECHNICAL DATA TYPE Length, mm Width, mm Height, mm Belt Area, m2 Belt Speed, m/min 3 Wash Water, m /hr. Air Consumption, m3/hr. Motor Power, kW
BFP 1.1 T 3500 1430 2200 21.5 2 – 10 8.5 1 0.75 + 0.55
BFP 1.6 T 3500 1930 2200 31.5 2 – 10 13 1 1.1 + 0.75
BFP 2.1 T 3500 2430 2200 41.0 2 – 10 16 1 1.1 + 1.1
BFP 2.6 T 3500 2930 2200 50.7 2 – 10 21 1 1.1 + 1.5
Krofta Engineering Limited Durga Bhawan, A-68, FIEE Complex, Okhla Industrial Area Phase-II, New Delhi – 110020. www.papermart.in / August-September, 2020 | 29 EPBX : +91-11-4724 2500 | E-mail: krofta@kroftaengineering.com | Web : www.kroftaengineering.com
S•P•E•C•I•A•L F•E•A•T•U•R•E “With the installation of the IBS showering system, water consumption has been drastically reduced from 2900 m3/day to 2200 m3/day, that is, we have been able to achieve the total reduction of 700 m3/day.” less or even mechanical face and lip seal where water requirement is almost nil. •
Mr. Deepak Jindal, Head – Environment, Naini Group Paper Mart: How do you implement the water treatment process to facilitate the recycling of water and what are your different wastewater treatment strategies? Deepak Jindal: Based on the studies conducted at our plant, the following are the recommendations and strategies with respect to water conservation: •
The major areas of freshwater consumption are showers on the paper machine, wet washing of raw material and bleaching section of the pulp mill. Thus, the mill must use appropriate techniques to clarify paper machine backwater for further reuse to the best possible extent.
•
Use of high consistency pumps helps avoid unnecessary pulp dilution.
•
Segregation of colorless/low COD load effluent streams and reuse/ recycle with or without treatment in the process to the best possible extent.
•
Mill may also use mechanical seal pumps or ceramic-based pumps where water requirement is very
Use of new generation pulp washer to minimize the water requirement.
In view of the scarcity of water, the use of membrane filtration for the selected effluent stream will be useful in achieving system closure. The mills or association should promote R&D studies to assess techno-economic viability of these technologies. Also, regular water auditing is an important tool that helps the industry to know the current status and also explore the possibility of minimizing water consumption by setting a target/ benchmark for individual section of the mill. The mill should also conduct an awareness programmes for the mill staff working on the shop floor and involve them to participate in giving suggestions to improve water conservation in a particular section. It must be noted that freshwater conservation leads to saving energy in pumping and handling of relatively smaller volume, lesser material loss, lesser effluent treatment cost and eventually lower the cost of production in an environmentally sustainable manner.
Retrofit strategy for the Conservation of Water in Pulp and Paper Mill. Reaction system (reactors) Once the route of chemical transformation of the process is known, the reactor system design is then considered. This involves the examination of a three-way tradeoff between equipment, level of conversion and reduction in water consumption. In the case of the bleaching process, the lower the
30 | www.papermart.in / August-September, 2020
amount of solids product (pulp) at the outlet of the reactor, the lower is the amount of water that is needed to reach the required concentration in the filtering stage. With knowledge of the characteristics of the bleaching reaction and reactor volume, the actual reaction rate can be determined. This information is then used to determine the additional reactor volume needed for more lignin to react. Also, the amount of freshwater consumption is linked to the level of lignin conversion in the reactor. Since freshwater is used to dilute the reactor outlet stream for it to be filtered downstream, as the amount of lignin that reacts increases, the lower the amount of solids is at the reactor outlet. This condition results in less freshwater being needed for dilution which enables to save water. In addition, warm water is added into the filter for furthering the removal of impurities from the cellulose. Water use system At this stage, a water pinch analysis is carried out. Let us consider the washing section of the process - that consists of a series of physical separations for the removal of impurities from the pulp coming out from the digester. This pulp is also known by the name of raw flesh because it has not been bleached yet. During this stage, a large amount of water is used. It is therefore important to ensure the implementation of techniques that leads to the reduction in the requirement of water. The large amounts of water used and the physical nature of the process are conducive for the implementation of the Water Pinch Analysis (WPA) technique which seeks to minimize the consumption of water. These conditions are also appropriate to pose an optimization problem by means of mathematical programming, seeking to reduce the total operating costs. Both techniques are effective for the analysis, synthesis and improvement
S•P•E•C•I•A•L F•E•A•T•U•R•E
www.papermart.in / August-September, 2020 | 31
S•P•E•C•I•A•L F•E•A•T•U•R•E of the water networks. Furthermore, they take into account the concepts of reuse and regeneration of water that have an impact on the generation of wastewater or effluents while minimizing water consumption.
•
Mental block in reuse / recycle of treated effluent / back water
•
Lack of awareness, trained manpower and monitoring facilities
Water regeneration for reuse
Steps taken at Naini Tissues for Water Conservation
Once exploited and completed all the options for the reduction of water consumption through the measures implemented in the first two layers of the onion diagram, the next step consists of the application of water regeneration techniques. At this level, different techniques for feasible decentralized regeneration of the effluents for water reuse should be evaluated. Among the typical regeneration technologies are those of physical, chemical and biological nature. The selection of the regeneration system should be based on a series of considerations such as equipment cost, operating costs, ease of implementation, availability, etc. Heat recovery system The last stage in the hierarchical strategy is to identify the options for reducing energy consumption through the maximization of the heat recovery and the quantification of direct savings generated by the simple reduction of water consumption. In some cases, when the economic scenario is favorable, the savings of steam can be channeled to the production of electrical power in cases where the process plant is integrated with a co-generation system. Major reasons consumption:
for
high
water
•
Low cost of water
•
Lack of optimum performance of pulp washers.
•
Carrying out of most operations at high dilution.
•
Lack of water audit/water balance/assessment of optimum water requirement
•
Lack of optimization of washer requirement on decker, pulp washers & paper m/c
•
Lack of fiber recovery units or low performance of existing fiber recovery units
•
Lack of adequate ETP facilities.
Secondary stage for wet washing of raw material and wetting of Bagasse wet bulk storage: •
100% reuse of treated secondary stage ETP effluent for wet washing of raw material and wetting of Bagasse wet bulk storage i.e. 4000 m3/day reductions in freshwater consumption.
IBS Showering System Installation of an efficient IBS showering system on the paper machine, wet-end to reduce water consumption drastically: •
With the installation of the IBS showering system, water consumption has been drastically reduced from 2900 m3/day to 2200 m3/day, that is, we have been able to achieve the total reduction of 700 m3/day.
Complete recycling of paper machine effluent to pulp mill by passing through Save-all: •
100% of paper machine backwater is recycled to pulp mill by passing through Save-all and is settled in a clear water tank. It brings about 2200 m3/day reduction in the freshwater consumption.
Installation of state-of-the-art, DCS based Biomethanation plant from Hydrothane (Netherland) for High effluent load drains: •
Effluent from Bagasse wet bulk storage and wet washing are treated in the Biomethanation plant before going to ETP and the recovered Biogas is used as a fuel in the boiler. COD reduction – 80% and BOD reduction – 90%.
Use of ETP treated effluent after
32 | www.papermart.in / August-September, 2020
Biogas Plant Other measures undertaken by the company includes: •
Counter-current washing in the unbleached section of pulp mill.
•
Approximate 70% countercurrent washing in the bleached section of the pulp mill.
•
Pulp mill unbleached section’s gland cooling is carried out with ETP treated effluent.
•
Use of foul condensate from Soda Recovery Plant on ODL washers for pulp washing.
•
Installation of Reverse Osmosis (RO) system followed by MVR (Mechanical Vapour recompression) system – Capacity 2000 m3/day
S•P•E•C•I•A•L F•E•A•T•U•R•E
www.papermart.in / August-September, 2020 | 33
S•P•E•C•I•A•L F•E•A•T•U•R•E RTMS system Installation at ETP •
Capex – Rs. 20 lakhs
•
Opex – Rs. 1 lakhs/annum
NABL-approved Effluent Laboratory at ETP.
MVR System Following the ZLD concept, after ETP tertiary treated effluent we have installed single stage RO followed by MVR for reject handing of RO system. The reusable water recovery (TDS<100 ppm) from the complete system will be 98%. The technology is completely new since the opex is very less as compared to conventional ZLD systems. However, the same is under fine-tuning stage. Moreover, there has been construction of gabion structures going on in the rain drains for high recharge of rainwater. PM: What kind of investment has been put into a company’s water treatment infrastructure? DJ: Factors influencing the cost of water treatment includes quality of the raw water, degree of treatment, the volume of water, size of the water treatment plant, treatment process & technology, regulating agencies and norms, recycling water quality, personnel, research gap, equipment, resources and financial status. Naini Tissues’ investment in the water treatment infrastructure includes: ETP 10 MLD – Aerobic, anaerobic and tertiary treatment. •
Capex – Rs. 10 crores
•
Opex – Rs. 1.25 lakhs/day
•
Capex – Rs. 10 lakhs
•
Opex – Rs. 2 lakhs/annum
PM: Could you highlight the pivotal technologies and measures undertaken to minimize the consumption and reduce and treat large wastewater discharge? DJ: Technologies and measures undertaken at Naini Tissues to minimize the fresh water consumption and reduce waste water discharge include: Installation of Efficient IBS showering system on paper machine, wet end to reduce water consumption drastically: •
Capex – Rs. 7 crores
•
Opex – Rs. 0.8 lakhs/day
Save-all and clear water tank for recycling of paper machine backwater in pulp mill. •
Capex – Rs. 0.40 crores
•
Opex – Rs. 0.2 lakhs/day
Water consumption reduced to 2200 m3/day from 2900 m3/day after installation of IBS showering system i.e. 700 m3/day reduction.
Complete recycling of paper machine effluent to pulp mill by passing through Saveall: •
100% recycling of Paper machine back water to pulp mill by passing through Saveall and settling in clear water tank i.e. 2200 m3/ day reduction in fresh water consumption.
Use of ETP treated effluent after Secondary stage for wet washing of raw material and wetting of Bagasse wet bulk storage: •
Recycling of ETP treated water 2 MLD – RO followed by MVR and ATFD. •
Testing
100% reuse of treated secondary stage ETP effluent for wet washing of raw material and wetting of Bagasse wet bulk storage i.e. 4000 m3/day reduction in fresh water consumption and almost equivalent reduction in waste water discharge.
Other measures undertaken by the company includes: •
Counter current washing in unbleached section of Pulp mill.
•
Approximate 70% counter current washing in bleached section of
34 | www.papermart.in / August-September, 2020
Pulp mill. •
Pulp mill unbleached section gland cooling is carried out with ETP treated effluent.
•
Use of foul condensate from Soda Recovery Plant on ODL washers for Pulp washing.
•
Installation of Reverse Osmosis (RO) system followed by MVR (Mechanical Vapour recompression) system – Capacity 2000 m3/day
Following the ZLD concept, after ETP tertiary treated effluent we have installed single stage RO followed by MVR for reject handing of RO system. The reusable water recovery (TDS < 100 ppm) from the complete system will be 98%. The technology is completely new since the opex is very less as compared to conventional ZLD systems. However, the same is under fine tuning stage. With the implementation of the mentioned technologies and practices, we have been able to reduce the freshwater consumption to 30m3/ton of paper and wastewater discharge is 25 m3/ton of paper. PM: Could you tell us about the recent developments taken place in your plant with regards to water management and treatment? What path-breaking steps have you taken to minimize your environmental impact and make your mill environmental-friendly? DJ: The Company has installed the Reverse Osmosis (RO) system followed by MVR (Mechanical Vapour recompression) system – with the capacity of 2000 m3/day. Following the ZLD concept and after the ETP tertiary treated effluent, we have installed a Single-Stage RO followed by MVR for the reject handing of RO system. The reusable water recovery (TDS<100 ppm) from the complete system will be 98%. The technology is completely new and the operating expense is very less as compared to conventional ZLD systems. However, the same is under fine-tuning stage.
S•P•E•C•I•A•L F•E•A•T•U•R•E
Paper Machine Rebuilds and Upgradation
Writing/Printing and newsprint Paper Plants up to 150 TPD.
Complete Pulp & Paper Plants and Equipments
Multilayer Kraft Paper Plants for lighter & heavy GSM up to 300 TPD. Multilayer Duplex Board Plant up to 300 TPD. Tissue Machine up to 50 TPD.
Technical Consultancy and Audits
R Mob : +91 75671 77136
www.papermart.in / August-September, 2020 | 35
S•P•E•C•I•A•L F•E•A•T•U•R•E “In the past few years, we have steadily reduced the consumption of fresh water in our facilities, and treated wastewater or recycled water is being used in the plantations – a practice that enables us to maintain and check our usage of water.” showers are being used to lower the consumption of fresh water. We have installed flow meters at all the sections to keep a strict vigil and monitor our fresh water usage.
Dr. Anil Kumar Naithani, Sr. General Manager (R&D and QC), Shreyans Industries Ltd.
chemical preparation.
We have instituted a counter current washing system in unbleach and bleach section of the pulp mill.
We ensure that only backwater is being utilized in pumps for sealing instead of fresh water. Furthermore, there are high efficiency brown stock washers which are followed by ODL washer with counter current washing system results in lesser consumption of water.
In the past few years, we have steadily reduced the consumption of fresh water in our facilities, and treated wastewater or recycled water is being used in the plantations — a practice that enables us to maintain and check our usage of water. In fact, approximately 40% fresh water consumption in raw material washing has been replaced by treated effluent. The treated effluent is also being used for gardening, floor cleaning and
In our water treatment system, the backwater of washers is used in self dilution. Afterwards, the foul condensate water is utilized in raw material washing/in raw material cooking and in pulp washing. Thus, we maintain a systematic and structured system to monitor and control our consumption of fresh water and use the treated water in a number of applications so as to conserve water at our mills.
Shreyans Industries Ltd. has initiated a number of in-house water consumption strategies in different operations of production. With the purpose to conserve water and reduce the use of fresh water at our mill, we have focused on utilizing recycled water in a number of ways and processes; for instance, machine backwater is being used in bleaching section, pulp dilution as well as in raw material washing. Moreover, the water-pressure in the main supply line has been reduced so as to minimize the fresh water consumption in various sections of the mill. If it is adjusted to be at high pressure, then, low-volume
ODL Plant
UASB Anaerobic Reactor
Treated effluent for plantation
Unbleached washer
Chemical preparation using treated water
Flow meter in recycled water line
36 | www.papermart.in / August-September, 2020
S•P•E•C•I•A•L F•E•A•T•U•R•E
www.papermart.in / August-September, 2020 | 37
E•X•P•A•N•D•I•N•G A•L•O•N•G
Jani Sales: Strengthening its Business With New 100 TPD MG Paper Plant
“We have decided to keep concentrating on the production of packaging grade products – such as MG Kraft Papers and MG Posters that are used in flexible packaging which haven’t been affected much during lockdown.”
Paper Mart interviewed Mr. Saifee Jani, Director, Jani Sales Private Limited, wherein he talks about the kind of impact the pandemic had created on the tissue paper industry and the different future goals of the company with regard to introducing new products as well as expanding the reach to untapped markets. Paper Mart: Kindly shed some light on the infrastructural capability, manufacturing facilities, manpower and quality control approach adopted at Jani Sales? Saifee Jani: With our marketing office in Mumbai, we have already commissioned our new MG paper plant at Sarigam, Gujarat. We have installed state-of-the-art machinery and equipped our unit with quality back-up facilities. Our production facility is first of its kind in Western India with 100 MT manufacturing capacity of MG papers in the GSM
range of 17-75. We have installed Yankee machine with MG cylinder. The paper machine’s deckle size for finished paper is 4.2 meters and it is designed to run at the maximum speed of 850 MPM. We have a highly qualified team of professionals who have the required technical skills in the area of production at the factory level, together with marketing professionals of proven expertise and background to effectively market the products manufactured. Presently, there are more than 200 skilled employees at our factory and the recruitment process is going on to expand our workforce. With more than two decades of trading experience in paper and paperboard industry, we are positioned as one of the leading wholesalers in the Indian paper industry. To ensure our products meet the set
38 | www.papermart.in / August-September, 2020
quality standards, we have invested on state-of-the-art pulping and stock preparation system which comprises of refiners, dispersal system, screening system, centricleaners, dilution profile headbox, scanner/GSM controller and ETP. The company has also installed Bruderhauf rewinder slitter and Simplex sheet cutter. PM: The Company has recently started the new MG paper plant. Could you tell us about your plans for
“
We have already started the manufacturing of 18-25BF MG Kraft Paper in the range of 20 GSM to 70 GSM
”
E•X•P•A•N•D•I•N•G A•L•O•N•G
“ MG Posters and MG Tissue Paper will be manufactured by end of October 2020, and soft tissue paper will be produced by the end of 2020
” the commercial production of tissue paper products? SJ: We have already started the manufacturing of 18-25BF MG Kraft Paper in the range of 20 GSM to 70 GSM. In addition, MG Posters and MG Tissue Paper will be manufactured by end of October 2020, and soft tissue paper will be produced by the end of 2020. PM: What are the various business strategies which have enabled you to adapt and mitigate the enormous impact of the COVID-19 pandemic and the crisis it has ensued? SJ: The outbreak of the COVID-19 pandemic has created a significant impact on the tissue paper market in India. As even today, the maximum consumption of the tissue and hygiene paper products in India takes place at marriages, parties, banquet halls, at different kinds of events, as well as in restaurants, hotels and corporates. Many of these organizations being
“
We are planning to introduce a new range of tissue paper products in the market by the year-end or by the beginning of 2021
”
under lockdown, and corporate offices (especially IT Companies) have been encouraging the “Work from Home” culture, which in turn has severely impacted the tissue paper market. The sales of the tissue paper products have just started picking up with the opening of offices and public places like restaurants; however, as it stands, even the market leaders are struggling to stay afloat and they have substantially reduced the prices of their products. That is to say, it will take at least a couple of months for the market conditions to further improve and the economy to recover. We have decided to keep concentrating on the production of packaging grade products – such as MG Kraft Papers and MG Posters that are used in flexible packaging which haven’t been affected much during lockdown. Besides, we are planning to introduce a new range of tissue paper products in the market by the year-end or by the beginning of 2021. PM: In what ways do you think that your business will shape out differently at the end of the FY2020-21 and what do you think would be the strategic approach for Jani Sales going forward? SJ: The Company will focus on manufacturing high-quality products for affordable prices. We will also concentrate on offering customers with unmatched quality control and after-sales services, which normally, is ignored by most of the mills. We are bound to succeed with total customer satisfaction approach. In addition, an ERP System is being implemented to provide necessary and relevant support to customers, suppliers, and personnel working in the company. We are optimistic to achieve success as we are driven with a total customer satisfaction approach. PM: What are the current markets you serve with your products-
domestically and internationally? Are there any plans to enhance your reach in newer geographies in the global marketplace in the near future? SJ: We are currently selling our products in India and Gulf countries. We are looking forward to now increase our penetration in Europe, Africa, Far East and Sri Lanka, by partnering with various export houses and export agents as we are well known since the last 40 years in paper trade in India. Moreover, we are going to appoint more distributors in several locations across the country to achieve PAN India distribution network in all metro and mini-metro cities. We are looking to partner with the converters of various renowned fast-food chains, with the aim to expand our reach in the food packaging product. PM: How do you think the Indian tissue paper market is positioned in the global marketplace and what are the key trends in this market segment? SJ: According to our experience in the domestic market, the current pandemic and the resultant lockdown had led to dismal sales and consumption of tissue paper products in the initial quarter of the current fiscal year. Except for the consumption in the healthcare sector - in medical facilities and nursing homes, every other institution had remained under lockdown for months, thereby, severely impacting the sales of the tissue and hygiene paper market in the country. As per our assessment and outlook, the lockdown is likely to be eased out by January 2021 to February 2021 with the further re-opening of public places. Correspondingly, it is expected that the demand may revive in the beginning of 2021 & around the same time; we are intending to introduce tissue paper in the market. PM
www.papermart.in / August-September, 2020 | 39
M•I•L•L F•E•A•T•U•R•E
Chadha Papers: Banking on Value Added Products “Chadha Papers has more of a sentimental value for us. It was the first industry that as a Group we established in 1992. It laid the foundation stones for our Group as a manufacturer. We were only a liquor trading company with a distribution network in Uttar Pradesh. This industry has been like a stepping stone for us — this is where we transitioned our operations from trading to manufacturing company. As a Group, we are positive that this industry is here to stay with us now”— Mr. Amanbir Singh Sethi
Mr. Amanbir Singh Sethi Director, Chadha Papers Ltd.
40 | www.papermart.in / August-September, 2020
M•I•L•L F•E•A•T•U•R•E
I
n an exclusive interview given to Paper Mart, Mr. Amanbir Singh Sethi, Director, Chadha Papers Ltd. shares his company’s business journey, product portfolio, plans to introduce value-added products and kind of impact the pandemic had created on the paper industry. Paper Mart: Please take us through the business journey of Chadha Papers while also charting out some of the most notable milestones? Amanbir Singh Sethi: Chadha Papers started its business journey in 1992. The company was owned and successfully run by the youngest brother in the family till 2008 — until the plant was closed. The mill was restarted in 2013 and was taken care by the middle brother — Mr. Rajinder Singh Chadha. I am his nephew, and
together with Mr. Chadha, we took a call to restart the paper mill in 2013. In April 2014, we started two of the three paper machines we had — one for kraft paper and another for newsprint manufacturing. Paper Mart: Tell us about the infrastructure and manufacturing capabilities — specifically when the mill was restarted in 2013-14 and the current setup? AS: Initially, we had two agro-based paper machines — PM1 (40 TPD) for kraft paper and PM2 (70 TPD) for writing & printing and packaging paper. We also had PM3 with a production capacity of 150 TPD. In the beginning, we started manufacturing on PM1 and PM3 having a joint capacity of 190 TPD. We also had an 8MW turbine setup in our plant.
When we restarted, the demand for newsprint was picking up — which was a good time to enter the market and we got good pricing for our product. In 2013-14, we started upgrading our paper machines for better production. We wanted to focus majorly on value addition — so we developed PM1 to manufacture absorbent kraft paper since the size of the machine was apt. The machine was upgraded to produce up to 110 TPD absorbent kraft paper. Moreover, as the previous infrastructure was agro-based, we made a huge investment in setting up the whole pulp mill and converted it to a recycled fiber-based machine. The machine speed was increased to 300-400 MPM for better and efficient production process. All the basic upgrades like section drive, QCS etc. that should have been done in the past
www.papermart.in / August-September, 2020 | 41
M•I•L•L F•E•A•T•U•R•E 6-7 years, were incorporated in the first step and then the machine was restarted. In 2015, we took a call to restart PM2. Initially, the machine was rebuild in phases to produce 110 TPD writing & printing and packaging paper. Gradually, basic upgrades were done to rebuild the machine to produce 170 TPD. We did another rebuild on PM2 and took it to 250 tonnes capacity running regularly at about 200 tonnes. Later, we shifted our focus on upgrading PM3 that produced writing & printing paper. In the beginning, the machine was running at a speed of 650 MPM— and to increase the speed we needed to change the headbox and QCS, with some upgrades required to be done in DIP. All the necessary upgrades from first bolt to the last bolt were delivered by Voith. After the upgrade, the machine speed was increased to 850 MPM. Nevertheless, for writing & printing paper we were using 650 MPM speed. In future, we intend to increase the capacity of PM3 to 250-270 TPD along with adding further grades in surface sizing and A4 Paper. PM: What products are you currently manufacturing in your existing setup? AS: Initially, we started PM2 to produce low BF packaging / writing & printing paper. However, we are now focusing to manufacture high BF packaging paper in the range of 28-35BF. Other than that, the PM3 has been primarily writing & printing paper machine — however, over the time the production was switched over in phases from newsprint to writing & printing grade. Chadha Papers has been a leading player in non-surface sized paper in Northern India. PM: Has there been any new product developments at Chadha Papers which you would like to talk about? AS: Our mission is to manufacture value-added and high priced papers. We are not running behind the tonnage at all — rather we are only focusing on high-value products. We have recently launched a shuttering base paper. This paper finds application in plywood and construction industries due to its wet strength and water-resistant
properties. Looking at the surging infrastructural development in India, the demand for shuttering base paper is expected to grow. Secondly, China has also been a leading manufacturer of shuttering base paper — however, with various restrictions on waste paper in China and other trade issues; we will be in a position to export as well. Beyond that we are looking forward to launch another high-value product — decor paper in the same absorbent market. It is primarily a wood-based product and is basically used as a top layer on sunmica. The decor paper has a huge market base, with Haryana alone having more than 1000 tonnes requirement, and adding all other places, 2000-3000 tonnes capacity is not a big deal. Apart from this, we are also focusing on manufacturing ‘paper for carry bags’ as we foresee a good market in this segment. PM: How do you go about product development at Chadha Papers?
42 | www.papermart.in / August-September, 2020
AS: Since we started, we have already put huge investment on the mill. We have recently hired a new team with a focus on specialty papers. I believe that the only area we should be investing in is research and development — it is one of the major core areas where we make sure a particular amount of fund is invested. One of the important aspects of our R&D procedure is spotting the correct product, suitable market and hiring a team which can make that product. Our R&D team is provided a fair amount of time on each machine to trial-run a new product. However, stopping the current production and taking a run of a new product is itself a major expense — and this is our investment in R&D. Further, once the R&D team is successful in developing any product, whatever is required to upgrade the machine for the new product development, we put investment into it without a second thought.
M•I•L•L F•E•A•T•U•R•E PM: How Chadha Papers addressed the obstacles faced during the recent lockdown? AS: One of the major challenges faced was the dip in the demand for writing & printing paper during the pandemic due to closure of school and colleges globally. The mill was closed for AprilMay 2020 period, and in May end we started the packaging and absorbent units. During the lockdown as our turbine was not in operation, the power to run the plant was sourced from the grid — which led to higher cost for us in the market in the last six months. Regardless of how the market was during lockdown, we bagged few tenders for writing & printing paper in May-June 2020. We had some orders during that period, however, beyond that there was no orders in the market. We had to actually keep the machine idle for minimum 20 days a month — due to which we incurred losses. PM: Keeping in view that every crisis gives us the opportunity to look into the future, how has Chadha Papers reflected and reconsidered its business, and turned the crisis into growth opportunities during the recent COVID-19 lockdown?
consuming product; hence, we made extra efforts to resolve this efficiently. Chadha Papers is blessed with 110 acres of land, of which 75 acres caters to on-site eucalyptus plantation. We are using every drop from our ETP for plantation. We are also a zero-liquid discharge (ZLD) mill, and amongst the few mills that have been granted land discharged permission from the
government. We are of opinion that if the Indian paper industry is to become more sustainable then further changes will have to be made to industrial practices within each stage of the papermaking — which includes social forestry management, pulp and paper production, paper usage, recycling, energy recovery, and final disposal. PM
AS: Firstly, this idle time made us think if tomorrow newsprint goes out and the sales volume of writing & printing is dropped, what would be next for us! The current pandemic has reinforced our thinking that having a bunch of higher value-added products that can be supplied to the market at any point of time is a must. Apart from this, there should always be 3-4 backup products running on the machine regularly. The positive part of the lockdown is that we have successfully managed to manufacture value-added products during that period. PM: What is Chadha Paper’s approach to environmental sustainability and social responsibility? Asees Singh Chadha: One major point that we are proud of in this whole process of restarting the mill in 2013 to running a formidable business operation today is that we heeded to our Chairman’s advice with regards to the environmental sustainability. We all are aware that paper is a highly water-
Mr. Asees Singh Chadha Director, Chadha Papers Ltd.
www.papermart.in / August-September, 2020 | 43
R•E•C•Y•C•L•E & R•E•I•N•V•E•N•T
Adler Paper: Turning Waste into Meaningful Resources
Adler Paper is the outcome of the merger of three companies - Victory Creations, Ultraprint and PaperWorks. The company is moving with an innovative approach and has recently introduced a mobile-based application - Adler Track and Trace. The company has carved its own niche in the recycled fibre industry by adapting to the ever-changing environment and building long lasting relationships globally.
Mr. Devang Vora, Founder (seated) and Mr. Hrishikesh Vora, CEO, Adler Paper
44 | www.papermart.in / August-September, 2020
R•E•C•Y•C•L•E & R•E•I•N•V•E•N•T
A
dler Paper is a Mumbai-based company that imports and deals in all types of waste paper and stock lots of paper rolls & sheets from all over the world. The company has an extensive global market presence and it provides long term disposal and procurement solutions to the Indian paper industry. In an exclusive interview with Paper Mart, Mr. Hrishikesh Vora, CEO, Adler Paper shares how the company was born, its out-of-the-box thinking & initiatives and their approach towards business and industry. Excerpts of the interview: Paper Mart: Could you please give us an overview of the business journey of Adler Paper? Also, elaborate on the market presence of the company. Hrishikesh Vora: Adler Paper is a cohesive amalgamation of Victory Creations, Ultraprint and PaperWorks, or as I like to say a seamless merger of three global recycling entities. The integration of these three established entities backed by the consolidated 100 years of experience is possible thanks to the vision and direction of my father Devang Vora. We were amongst the first in 19791980 to import waste paper into India in break bulk shipments. We have diversified into stocklots and waste paper and my father’s trust in my abilities has instilled confidence in me to grow this business onwards and upwards. We are based out of Bombay and we supply waste paper and stocklots from various locations – the USA, UK, Europe, Middle East into all across India. Our network of agents has helped us to reach customers of every region of India. We represent some of the top suppliers from these above-mentioned regions and we are looking to expand into unexplored markets in the near future. PM: What do you think are the key strengths of the company that has enabled you to make your mark in the paper recycling industry?
HV: There are a number of factors which has helped us to carve out our niche in the paper industry. Our razor sharp vision, high and stable flight path, systematic approach, innovative procurement and most importantly, our out-of-the-box thinking ability and ability to take calculated risks helps us to stay updated in this everchanging market and build long standing relationships. In terms of container shipments, be it 1 load, 2 loads, 20 loads or 100 loads – we can move it all.
Also, we are able to assure our suppliers and buyers a steady supply of certain special and difficult grades of paper and we are known for the supply of specialty grade paper. Buying OCC and mixed grades is relatively easy but we can move anything and everything & find a home & end-use for special grades. Thus, we have a diverse range of waste paper which is a unique advantage for us. In terms of container shipments, be it 1 load, 2 loads, 20 loads or 100 loads – we can move it all. PM: Has there been any recent development at Adler Paper that you would like to talk about? What are your future plans and growth strategies for the coming years? HV: Yes, absolutely. Firstly, we have incorporated technology into the way we work. We have made available our entire documentation process online. This enables work from anywhere in the world & there is no need to come to the office since all we need is a laptop and an internet connection. This gives us the freedom to work from any location and any time zone, especially in the uncertain times that we are experiencing now. We are also very pleased to inform you that Adler has launched its own web and mobile-based application called ‘Adler Trace and Track’. In our
‘Adler Trace and Track’ is the one-stop-shop for all the orders booked with us as one can use the application for tracking the containers and to get the status of the pending orders, if there are any. pursuit of making the entire process of tracking containers easier for our customers – we have developed this software which gives you a limited access into our system and further reflects the transparency in our approach. ‘Adler Trace and Track’ is the one-stopshop for all the orders booked with us as one can use the application for tracking the containers and to get the status of the pending orders, if there are any. One can access the software on Google Play Store (for android users), Apple App Store (iOS) and moreover, we also offer a web access to the customers using their desktop or laptops. To sum up, one would no longer need to call us for the weekly shipment status charts as we have handed over that power to our customers. Anyone from their organization will be able to access this and track the containers and get status reports, which makes the process very easy. PM: Earlier this year, the Material Recycling Association of India (MRAI) had put forth the idea of setting up “recycling zones” and “shredding centers” that can become hubs of scrap management. How do you think this proposal is favorable in the context of the Indian paper industry? HV: I think it is a great idea and we need to implement this plan. As a matter of fact, since Indian landfills are getting exhausted, there is a strong need for establishing “recycling zones” and “shredding centers” that can become hubs of scrap management in different regions in our country. Although there is enough money and
www.papermart.in / August-September, 2020 | 45
R•E•C•Y•C•L•E & R•E•I•N•V•E•N•T investment potential in India to set these up, one major prerequisite is the support of the Government of India to be extended to bring this plan into action. The plan would require large tracts of space for setting up these zones and centers and thus, we will need the Government’s aid to build the infrastructure and execute this proposal. PM: As per the Confederation of European Paper Industries, India is one of the leading destinations for most of the waste paper from the US and Europe for recycling purposes. What are the regulations for the import of waste paper in our country and the challenges as the demand for waste paper is increasing every year? HV: To begin with, we need stricter regulations in place. While I am all for increased sales of imported waste paper into India – India should not be used as a dumping ground. It is extremely important to source responsibly and have regulations in place for good quality imported waste paper to come into the Indian market that goes for re-pulping rather than filling our already full landfills more and more. It is extremely important to source responsibly and have regulations in place for good quality imported waste paper to come into the Indian market that goes for re-pulping.
PM: The present recovery and utilization of waste paper in India are relatively low as compared to other developed nations. How do you think that it can be increased to meet the raw material demand? HV: In India, do we need proper
channels and methods for the recovery of waste paper? One thousand percent, yes! If we have a proper recovery system in India like the rest of the world has - three-bin system or fourbin waste separation system- where we segregate the waste at the source – the amount of waste paper we could recover domestically in India will be tremendous. In fact, we are talking about millions of tons of waste paper not going to landfill every year, which is an enormous amount that we could recover. The availability of raw materials (old and used paper) for the Indian paper industry can increase manifold if
institutions and more households segregated the paper waste and sold it to the recycling units. The domestic waste paper sector will explode exponentially and financially if we can achieve this. However, it can be made possible only with the adequate support and relevant policies of the government to enhance the recovery of waste paper in our country. PM: How the COVID-19 pandemic has affected the recycled fiber industry and how do you foresee the future? HV: The pandemic caused by the COVID-19 outbreak has made us realize how the world can change overnight. We must change with it
46 | www.papermart.in / August-September, 2020
and if we do not change and not adapt to the environment – the competitive edge we offer to the customers would likely be gone. The industry is going to have to be smart and resourceful in the context of raw material. As we evolve, it is certain that if you have waste paper stocked in your yard at any point in time – you are the King. That being said, it is of utmost importance to plan wisely, and making sure that you have enough waste paper stocks in the yard and in the pipeline as it is the most valuable resource. Moreover, it can be said with absolute certainty that in the post-pandemic world, e-commerce is going to flourish and grow at a tremendous rate. As a result, the packaging segment is also going to witness higher growth in the coming times. Although it is true that there are some challenges that we need to address and it is not going to be easy, but then, the Indian paper industry is also uniquely positioned and given the right set of market conditions, we will flourish and bloom. I am quite excited for what the future holds in store for us. PM: Is there anything else that you would like to add to our interaction? HV: I would say, to be a knowledge partner is no mean task. One needs to know the market very well and it is essential to be an expert in all technical, logistical and actual aspects of trade. Thankfully, my father and myself are uniquely positioned and experienced in flying across continents to constantly build new trade relationships. We are confident that Adler is here to stay for the next 100 years. As we are in the post COVID-19 new world reality, we are eagerly looking forward to all the challenges that come with it. PM
R•E•C•Y•C•L•E & R•E•I•N•V•E•N•T
YUNDA PAPER MACHINERY
Supplier of Complete Set of Stock Preparation and Approach System in China Established in 1981, Yunda specializes in researching and manufacturing of stock preparation equipment. The main products include the Waste Paper Bales Dry Separating & Screening System (patented in China), Chain Conveyor, Drum Pulper, D Type Continuous Pulping System, Drum Coarse Screen, Super Screen, Waste Paper Reject Classified Treatment, Mid Consistency Pressure Screen, Low-Pulse Inflow Pressure Screen, High & Mid Consistency Hydrapulper, HD Cleaner, Fiber Sorter, Reject Sorter, Double Disc Refiner, Disc-Thickener, Flotation Deinking Machine, Conical Refiner, and Hot Disperser System, etc.
Star Products
Drum Pulper
Chain Conveyor
The Waste Paper Bales Dry Separating & Screening System
Mid Consistency Pressure Screen
Double Disc Refiner
Mid Consistency Hydrapulper
Agitator
D-type Continuous Pulping System
Headbox Screen
SSC Super Screen
Zhengzhou Yunda Paper Machinery Co., Ltd. Address: 168 Shiji Ave., Xuedian, Job Requirements: 1. Bachelor degree or above, major in Pulping and papermaking or other related fields. Xinzheng, Henan, China Tel.: +86-0371-62581860 2. Min. 5 years' experience in pulp and paper or relevant industry. Fax: +86-0371-62586686 3. Fluency in speaking and writing English. Whoever can also speak Chinese has priority. www.papermart.in / August-September, 2020 | 47 Web: www.en.zzyunda.com CV receiving email: info@zzyunda.com Email: info@zzyunda.com
Recruitment: Sales Engineer
P•R•O•D•U•C•T I•N•N•O•V•A•T•I•O•N
IBS Paper Performance Group : Paper Making Reinvented The IBS Paper Performance Group is a leading supplier of technologies and services for the global paper, board, pulp and tissue industry. With over 50 years of experience, IBS is the unrivalled expert for paper machine optimization. Therefore, a professional team of more than 30 papermaking experts around the world is committed to boost its customers’ performance forward – everyday!
Mr. Alfred Staber, Area Sales Manager, IBS Paper Performance Group, Austria
Interview with Mr. Alfred Staber, Area Sales Manager, IBS Paper Performance Group, Austria. Q: What is that makes IBS PPG so successful in the pulp and paper industry?
Q: IBS is called to be the inventor of intelligent dewatering solutions in the wire section. What is the iTABLE™?
AS: The IBS Paper Performance Group stands for innovative technologies and excellent products in the world of papermaking. Our comprehensive portfolio covers a wide range of applications. We have eleven strong brands under our roof, all with their own technology and history. And we are not only providing machine components — with over 50 years of experience in the industry, we are providing tailor-made system solutions paired with technological know-how to our partners worldwide. A further secret of being successful is for sure that our development team never stops working; we are continuously improving our solutions. Additionally, IBS employees are experts in each section of the paper machine. A team of well-experienced engineers and papermakers is evaluating each inquiry to find the best solution for every application. This is what makes us strong– we are always one step ahead.
AS: The idea of inventing an intelligent forming table was already conceived in the last century. After years of research and development, the first fully adjustable wire table was installed in 2007 — called iTABLE™. It gives papermakers flexibility in terms of changing foil angles, heights, pitch, and vacuum settings - and the best part is: Those settings can be done by pushing a few buttons within a couple minutes. The iTABLE™ is not a standard item, it is a tailor-made solution and involves an extensive survey of the machine and the papermaker’s targets. Many mills implement the iTABLE™ in steps. In the last few years, IBS has equipped many machines with automatic vacuum control systems as the 1st step of an iTABLE™ concept. Vacuum has been one of the neglected areas in paper machines and we can have a whole separate discussion on this topic another time. Q: How many iTABLE™ have been
48 | www.papermart.in / August-September, 2020
installed already? AS: Today, more than 160 iTABLE™ have been already installed worldwide. The first one was installed in India in 2018, and another one will be installed in the 2nd half of 2021. Q: Which machines can be equipped with an iTABLE™? AS: In India, we had the experience that many machines have to produce small order quantities and therefore paper grades need to be changed very often — the best conditions for an iTABLE™. Besides a very few dedicated newsprint machines, all medium and large machines in India are perfect candidates for an iTABLE™.
Today, more than 160 iTABLE™ have been already installed worldwide. The first one was installed in India in 2018, and another one will be installed in the 2nd half of 2021.
P•R•O•D•U•C•T I•N•N•O•V•A•T•I•O•N Q: What is your impression of the Indian paper industry? AS: The Indian paper industry is one of the fastest growing markets in the world. Considering the number of paper machines currently in operation, India has a huge potential. IBS PPG has a strong presence in India thanks to its technical capabilities, know-how, and a network of IBS’s representative in India. Our target is to bring high sophisticated products, system solutions and environmentfriendly technologies (Energy and water saving products) to our Indian customers. With regard to COVID-19, I am quite sure that this crisis is not permanent and the Indian paper industry will revive soon and return stronger than before. Our target is to bring high sophisticated products, system solutions and environmentfriendly technologies (Energy and water saving products) to our Indian customers. Q: Environment is one of the most important things nowadays. What contribution does IBS PPG make? AS: Environment-friendly and resource-saving products are one of the main focuses of IBS PPG. We spend 5% of our turnover in research & development. You may have heard of ultra-high-pressure cleaning systems for machine clothing called “FabriCare”& “FabriClean”. These systems clean forming fabrics, press felts and dryer screens online at a pressure between 60 and 280 bars with fresh water only — without any chemicals, steam or vacuum. Compared to conventional highpressure showers, these systems save 80% to 90% of fresh water. Nearly 20 FabriCare/FabriClean systems have been already installed in India and an additional 15 are lined-up for commissioning in 2021. Currently, the IBS Paper Performance Group is expanding it’s headquarter in Teufenbach-Katsch (Austria) with a distinctive building — the IBS Tower. It is not only intended to create new space for further growth, but also to put down a marker. PM
Currently, the IBS Paper Performance Group is expanding it’s headquarter in Teufenbach-Katsch (Austria) with a distinctive building — the IBS Tower.
“The building is intended to make our internationally extremely successful company and its attractive career opportunities visible to the outside world,” as said by our owner Mr. Klaus Bartelmuss.”
STEEL WORKS
www.papermart.in / August-September, 2020 | 49
C•A•S•E S•T•U•D•Y Paques India: Closed Loop Operation With Biological Treatment in Indian OCC Industry Producing odour free paper and water disposal problems are perpetual concerns for the Indian OCC Industry, more so due to the stringent rules of PCB (Pollution Control Board). The wastewater characteristics from the OCC mill which does not have biological treatment, contains high (please refer table 1 before BIOPAQ®ICX) COD – 57000 mg/l, VFA – 300 meq/l, Calcium – 5100 mg/l, etc. These composition leads to more ground pollution. Hence, these plants should be operated with ZLD (Zero Liquid Discharge) to avoid water disposal to ground by having suitable treatment scheme. And because of such high concentration of VFA in the water, Akshera struggled to produce odour free paper.
in several process steps done by a mixed culture of microorganisms. The process steps of anaerobic COD conversion can be summarized in two major process steps: 1.
Acidification
2. Methane formation During the acidification process large organic compounds are converted into volatile fatty acids (VFA). These are small organic molecules, mainly acetic acid. This acidification process does not significantly change the COD concentration itself, but just changes the composition of the COD. Large organic molecules are basically “broken” into smaller organic molecules, which subsequently serve as food for the methane producing micro-organisms.
An anaerobic BIOPAQ®ICX reactor from Paques has been installed at Akshera as part of an effluent treatment plant (ETP) in order to maintain low concentrations in the mill and simultaneously produce biogas from the COD. The ETP treats currently 1000 m3/dof process water with one paper machine in operation. Due to implementation of the BIOPAQ®ICX reactor the actual SCOD concentration in the mill water is 5000 mg/l and the calcium concentration is 600 mg/l, which is approximately ten times less compared to the previous situation without the BIOPAQ®ICX reactor and is resulting in odour free and improved strength of the paper. Before ICX commissioning, the paper mill was operating in closed loop without COD reduction, resulting in accumulation of COD and VFA. Because of the presence of concentrated amounts of COD and VFA in the loop, odour in the paper was high. Due to closed loop without treatment of water COD, VFA and Calcium concentration increased drastically in the loop water. VFA in the water is major reason for abnormal odour in the paper. Akshera decided to control the odour in the end product and installed Paques BIOPAQ®ICX reactor. After ICX commissioning, the plant was successfully able to produce odour free paper and notably the paper stiffness also improved.
In the reactor the anaerobic micro-organisms convert the COD present in the pre-acidified wastewater into methane (CH4) and carbon dioxide (CO2). The generated biogas is collected in the headspace of the reactor and subsequently transported to a gas buffer or other gas processing unit. The treated wastewater is separated from the biomass in the separators and leaves the reactor with a significant reduction in its COD concentration.
Technology Supplied:
Schematic overview of BIOPAQ® ICX reactor:
Paques supplied BIOPAQ® ICX technology, our third generation anaerobic reactor to Akshera, as a part of the ETP to handle COD and VFA concentrated paper process water from the mill. The BIOPAQ®ICX reactor is an anaerobic reactor designed to biologically convert organic pollutants (measured as COD) present in the wastewater into biogas. Installing a BIOPAQ®ICX reactor can have the following objectives:
Figure 1:
•
To bring down loop COD less
•
To bring down VFA in the loop lower side
•
To produce odour free paper
The anaerobic conversion of COD (organic compounds) into methane is a biological process, which can be divided
50 | www.papermart.in / August-September, 2020
The acidification process occurs partly in the pre-treatment upstream of the anaerobic reactor (e.g. sewer system, buffer/acidification tank) as well as inside the anaerobic reactor. The acidification which takes place upstream of the anaerobic reactor is called “pre-acidification”. In most cases a certain degree of pre-acidification is desired, because this enhances the performance of the anaerobic reactor as well as the biomass quality. In some industries, the acidification process is less relevant (e.g. chemical industry) as the COD is already present in the form of organic acids or the specific COD compounds do not acidify in a pre-treatment.
C•A•S•E S•T•U•D•Y Plant Operation: ICX commissioning started on 21st July 2020 with Paques BIOPAQ® ICX reactor. Remarkably, the plant stabilized within 2 weeks from the starting date. Also, the plant is making Kraft paper as final product, only one machine is under operation out of two. After implementing Paques BIOPAQ® ICX system Akshera is now able to produce odour free paper, which was earlier a major problem for them. Due to 100% closed loop with controlled critical parameters (COD, VFA) the water discharge is not required hereafter and the plant is now able to maintain quality of the paper by re-circulating ETP treated water to the mill.
in the range of 5000 to 5500 mg/l after BIOPAQ®ICX commissioned. Now without adding more fresh water Akshera is able to maintain loop COD concentration. Before BIOPAQ®ICXcommissioning water COD was 57000 mg/l. BIOPAQ®ICX DAF outlet SCOD (mg/l) 7000 6000 5000 4000 3000 2000 1000
Odour Issue:
0
Odour control is a major challenge in OCC mills. The odour in the paper is caused by high Volatile Fatty Acids (VFA) and Sulphides. These two organics and inorganics create a foul smell when they are not under control. Operating plant with closed loop with adequate anaerobic and aerobic treatment is the solution for the said issue. These concerns have been successfully tackled in Akshera by operating adequate anaerobic and aerobic, thus helping them to produce odour free paper. The below results were achieved after BIOPAQ® ICX installation: Table 1: Water composition in the mill before and after implementation of BIOPAQ®ICX reactor& final treated water S. No
Parameters
Before BIOPAQ® ICX
After BIOPAQ® ICX
Final treated water
1
pH
5.56
6.5 – 7.2
7.5 – 8.0
2
TSS (mg/l)
800
< 300
< 150
3
TDS (mg/l)
24400
9000 - 11000
< 6000
4
Calcium (mg/l)
5130
600
< 300
5
VFA (meq/l)
300
30 - 40
<2
6
Paper odour
Yes
No
----
7
SCOD (mg/l)
57700
5000 - 5500
< 700
As per above table the COD and VFA concentrations in the mill have become ten times lower after the implementation of the BIOPAQ®ICX reactor from Paques. The improved water quality in the mill has resulted in odour free paper and has also improved the strength properties of the same. Graphical Representation:
Graph 2: ICX COD removal efficiency: With reference to Graph 2: ICX is removing 70 to 75% COD and balance COD removed from aerobic tank. At the outlet of aerobic we are able to maintain COD in the range of 600 to 700 mg/l. 100% aerobic outlet water is further utilised for stock preparation. ICX SCOD removal efficiency (%) 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00
ICX efficiency (%)
Graph 3: ICX effluent VFA: BIOPAQ®ICX reactor is bringing down VFA from 40 meq/l to 5 meq/l. The residual VFA from BIOPAQ®ICX reactor further treated in post treatment. These VFA further reduced to <2 meq/l at aerobic outlet. ICX Effluent VFA 18 16 14 12 10 8 6 4 2 0
Graph 1: Inlet COD to ETP after DAF With reference to Graph 1: DAF outlet COD is maintaining
ICX effluent VFA (meq/l)
www.papermart.in / August-September, 2020 | 51
C•A•S•E S•T•U•D•Y Closed loop circuit after BIOPAQ® ICX: Figure 2:
Fresh water addition equal amount of evaporation loss
Evaporation loss
Stock preparation
Paper machine
Surplus sludge from aerobic system
Collection tank
Sedicell underflow sludge
Belt press
Secondary clarifier
Conditioning tank
Sedicell
ICX biomass holding tank
Aeration tank
Biogas to flare system
BIOPAQ® ICX
Conclusion: With reference to the above table and graphs the integration of an ETP including a BIOPAQ® ICX reactor in a closed loop is possible without installing any tertiary treatment like UF, RO and Evaporation. This is evident that Paques BIOPAQ® ICX reactor can operate with closed loop in OCC mills. Due to this more capital and operational expenses can be reduced. The major problem of water disposal and odour free paper production will no more be an issue in OCC mills. With the operation of BIOPAQ® ICX and adequate aerobic system we are maintaining mill water COD and VFA in the loop which will ensure odourless paper production. The entire treated water from ETP can meet paper mill process requirement and hence fresh water addition in the system will not be required anymore. This will help our customers to optimize fresh water consumption and the plants which is located in drought area to achieve their production capacity with available water resources. The aim of the project is to:
TEST REPORT
Report No. : TR:TX:1144040786
TEST REPORT
DATE : 27-Aug-20
Report No. : TR:TX:1144040786
DATE : 27-Aug-20
R E S U L T S
REQ
ODOUR TESTING SNV 195 651
Odour Less (G-1)
AKSHERA PAPERS S F NO 557 5 BHAVANISAGAR ROAD, PASUVAPALAYAM Tamil Nadu, Erode-638451 IN CONTACT PERSON : MR.VASANTHKUMAR THE FOLLOWING SAMPLE(S) WAS/WERE SUBMITTED AND IDENTIFIED BY/ON BEHALF OF THE CUSTOMER AS :
Grades 1= odourless 2= weak odour 3= tolerable odour 4= annoying odour 5= intolerable odour
PRODUCT DESCRIPTION COLOUR COUNTRY OF DESTINATION COUNTRY OF ORIGIN SAMPLE RECD ON
PAPER KHAFT PAPER (180 GSM) SUBMITTED GREY INDIA INDIA TESTING PERIOD : 24-Aug-20 - 27-Aug-20 18-Aug-2020
TESTS ***** End of Report ****
Page 4 of 4
JOE No. : 2044820667
Control No.:1144543970
This document is issued by the Company under its General Conditions of Service printed overleaf or available on request and accessible at http://www.sgs.com/terms_and_conditions.htm and Terms and Conditions for electronic documents www.sgs.com/terms_e-document.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any holder of this document is advised that information contained hereon reflects the Company's findings at the time of its intervention only and within the limits of Client's instructions, if any. The Company's sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. Unless otherwise stated the results shown in this test report refer only to the sample(s) tested and such sample(s) are retained for 30 days only. This document cannot be reproduced except in full, without prior approval of the Company. SGS India Pvt. Ltd.
JOE No. : 2044820667
Member of the SGS Group (SGS SA)
FAIL
REMARKS REFER RESULT
Page 2 of 4
Control No.:1144543970
This document is issued by the Company under its General Conditions of Service printed overleaf or available on request and accessible at http://www.sgs.com/terms_and_conditions.htm and Terms and Conditions for electronic documents www.sgs.com/terms_e-document.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any holder of this document is advised that information contained hereon reflects the Company's findings at the time of its intervention only and within the limits of Client's instructions, if any. The Company's sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. Unless otherwise stated the results shown in this test report refer only to the sample(s) tested and such sample(s) are retained for 30 days only. This document cannot be reproduced except in full, without prior approval of the Company. SGS India Pvt. Ltd.
Consumer and Retail, 134, 2nd Floor, Sivasakthi Nagar, College Road, Tirupur-641602. Tel:+ 91 421-4630100
PASS
ODOUR TESTING
Consumer and Retail, 134, 2nd Floor, Sivasakthi Nagar, College Road, Tirupur-641602. Tel:+ 91 421-4630100
Member of the SGS Group (SGS SA)
Authors: •
Kapil Thomas - CEO, Akshera Papers, Pasuvapalayam, Sathyamangalam, Erode, Tamil Nadu, India
•
Silvius Mark - Process & Industrial Specialist, Paques BV, Netherlands
The above two target has been achieved after the commissioning of Paques BIOPAQ® ICX. Akshera is now able to produce odour free paper in Indian market with a closed loop system.
•
Suchit Dekivadia - Business Director, Paques India, Chennai, Tamil Nadu, India
•
Ajay Wakodkar - Head Paper & Pulp, Paques India, Chennai, Tamil Nadu, India
Odour Testing Certificate
•
Elanchezhiyan - Asst. Manager – Paper & Pulp, Paques India, Chennai, Tamil Nadu, India
The Kraft paper (end product) from Akshera was certified as odour free by renowned third party testing agency, SGS Laboratories.
•
Dr. Grasius M G - B. Sc. (Engg), M.Tech., PhD in Environmental Engineering (IIT - Kanpur)
•
Produce odour free paper
•
Improve paper stiffness
52 | www.papermart.in / August-September, 2020
R.S.ENGINEERS
Manufacturers of : • Doctor Blades • Doctor Holders • Doctoring Systems
• Doctor Oscillation Systems • Felt Stretchers • Autoguides
Add. : L-6200/9, 4th Phase, G.I.D.C., Vapi – 396195, Gujarat, India Ph.: +91-260-6543577, Cell : +91 9898130415, +91 9227830415 Email : ayaz@rs-engineers.com, sales@rs-engineers.com Website : www.rs-engineers.com
HAITEK INDUSTRIAL FABRICS PVT. LTD. Haitek Industrial Fabrics Pvt. Ltd. is a fabrics manufacturing company for Paper Industry, Non-Woven Industry, Water Treatment Industry, Chemical Industry etc...
Our Portfolio of Products Include 1. Paper Industry • Single Layer Forming Fabric (Five Shaft & Eight Shaft) • One & Half Layer Forming Fabric (Ten Shaft) • Double & 2.5 Layer Forming Fabric • Spiral Link Dryer Fabric CFM 750-1250 • Woven Screen CFM 250-550 • Press Felt for Paper Making • Sludge Press Felt CFM 350-550 2. Non -Woven Industry • Spin Belt 3. Water Treatment & Chemical Industry • Stuffed Spiral Link Fabric • Conveyor Fabric • Filtering Fabric
HAITEK INDUSTRIAL FABRICS PVT. LTD. Plot No 17, Sector 18 Phase-III, Industrial Estate, Barhi-Ganaur, Sonepat – 131101, (HARYANA) Mob: 9999906717,7807299938 Email: max@haitek.in, sachin_guleria@haitek.in Web: www.haitek.in
www.papermart.in / August-September, 2020 | 53
I•N•D•U•S•T•R•Y W•A•T•C•H
A.Celli Paper: Making New Strides Headquartered in Lucca, Italy, A.Celli Paper S.p.A. is a global leader in the supplying of machineries and advanced technologies for the paper and nonwovens market. The company has recently acquired PMT ITALIA - PAPER MACHINERY TECHNOLOGY, a company operating in the production of machinery for tissue and paper industry.
A.
Celli Paper S.p.A. is a company with a history of more than 75 years in the world paper market, providing advanced technology products and solutions. It specializes in the design of complete turnkey plants, in the manufacturing and rebuilding of tissue machines, and rewinders for tissue, flat paper and cardboard. With a view to continuous evolution and improvement of the range of products and services, the A.Celli Group completes its offer with business units dedicated to the development of: •
Roll handling & packaging systems, automated guided vehicles (AGV) and customized solutions for the automatic warehousing of reels, pallets, finished or semi-finished products
•
Industry 4.0 solutions for the digitalization of industrial processes and real-time data collection for the optimization and traceability of production, maintenance and remote control processes
•
Flexographic printing solutions on tissue, non-woven fabric and PP/PE film
Current Vision
Situation
and
Strategic
According to the latest forecasts, in Italy, the current year will close with a public debt of 194 billion above the levels of the end of 2019 and with a GDP of -10.5%. The Italian economy, therefore, which already showed clear signs of stagnation, suffered a strong backlash given by the spread of the pandemic. Despite this situation, at A.Celli, we did not want to bend to the logic described above and we tried to look further ahead. In fact, during 2020, A.Celli Paper took an important strategic step: the acquisition of PMT, a historic company operating in the machinery sector of the paper and tissue industry. With the entry of PMT into the perimeter of A.Celli Paper, the range of products and services was expanded and completed, thanks to the synergies that have been created between the organizations. In particular, the technologies developed in the field of packaging papers, cardboard, cardboard, graphic papers, etc. they were again made available to Italian and foreign customers thanks to the skills and know-how acquired. Strong impetus
54 | www.papermart.in / August-September, 2020
Mr. Simone Morgantini, Marketing & Communication Manager, A.Celli Group
I•N•D•U•S•T•R•Y W•A•T•C•H A.Celli Paper took an important strategic step: the acquisition of PMT, a historic company operating in the machinery sector of the paper and tissue industry. was given to customer service in order to guarantee continuity and reliability of service to those who still use the former Beloit/PMT technologies. Maintaining this wealth of knowledge in Italy, in a strategic sector such as that of paper production, has meant making an important choice that will benefit the entire supply chain, including the district of Lucca. Technological Innovations A.Celli Group has developed a series of solutions that use the logic of artificial intelligence (AI) in the form of machine learning to analyze big data in order to determine the operational efficiency of each machine on the production lines of multiple production sites. The final objective of this process is to provide data processed in real time in order to measure the production efficiency of the individual plant, create information databases to compare the different performances (energy, production, quality, etc.), optimize the downtime for maintenance, interfacing the production departments with management control and various other potentials. Finally, A.Celli Nonwovens, boasting thirty years of experience in the nonwoven fabric sector, specializing in winding, rewinding and reel handling lines, has provided state-of-the-art technologies for the production of this fundamental material necessary for the production of masks, health care, hygiene, etc. to the customers all over the world. PM A.Celli Group has developed a series of solutions that use the logic of artificial intelligence (AI) in the form of machine learning to analyze big data in order to determine the operational efficiency of each machine on the production lines of multiple production sites.
www.papermart.in / August-September, 2020 | 55
S•U•S•T•A•I•N•A•B•L•E P•A•C•K•A•G•I•N•G
The LEGO Group: Pledges 100% Sustainable Packaging by 2025 The LEGO Group aims to make 100 percent of its packaging from more sustainable materials by the end of 2025. This involves removing all single-use plastic from its packaging. Paper Mart interviewed Mr. Tim Brooks, Vice President of Environmental Responsibility, The LEGO Group, wherein he stated that the Danish toymaker is currently piloting whether it can potentially use bio-elements more widely in the portfolio and exploring opportunities with recycled plastics.
Mr. Tim Brooks, Vice President of Environmental Responsibility, The LEGO Group
Paper Mart: The LEGO Group has announced that it would stop using plastic bags inside its boxed sets and replace them with paper packaging? What prompted the LEGO Group to consider this move? Tim Brooks: We have made a series of moves over the past 10 years to build a better planet for future generations; but as society starts to recover in a post-COVID world, we believe it’s increasingly urgent and important to prioritize environmental and social activity. It was in 2015 that we had announced our ambition to make our products and packaging 100% sustainable. In 2018, we brought forward the packaging target to 2025 – replacing single-use plastic bags in LEGO boxes with paper bags is a part of this ambition. We received hundreds of letters from children about the environment, with many asking us to remove single-use
It was in 2015 that we had announced our ambition to make our products and packaging 100% sustainable.
56 | www.papermart.in / August-September, 2020
S•U•S•T•A•I•N•A•B•L•E P•A•C•K•A•G•I•N•G
We received hundreds of letters from children about the environment, with many asking us to remove singleuse packaging. We have been exploring alternatives for a while, but these letters have inspired us to be proactive in making the change. packaging. We have been exploring alternatives for a while, but these letters have inspired us to be proactive in making the change. PM: What are the sources of the paper you would be using for packaging? Is it from sustainable sources? TB: The paper that will be used in LEGO boxes from 2021 will be Forest Stewardship Certified paper to ensure that it is sustainably sourced. PM: LEGO bricks themselves are made of plastic. What alternative materials the company is exploring or have introduced in the past few years? TB: In 2018, when we first launched bioelements, we used bio-polyethylene for around a dozen of our botanical elements. During the past few years, we have expanded its use and we now make around 80 elements out of bio-
polyethylene. Over the next three years, we will continue to work to expand the use of bio-polyethylene, for example, elements like accessories, such as minifigure hair, which lend themselves to the slightly softer properties of biopolyethylene. At the same time, we will continue to explore other sustainable materials for use in our bricks such as renewable or recycled materials. PM: As consumers/end users continually push for more sustainable/ greener solutions, what are the other packaging concepts that you are planning to introduce? TB: By the end of 2025, we aim to make 100% of our packaging from more sustainable materials. This involves removing all single-use plastic from our packaging. PM: The LEGO Group has set a target to make its products from sustainable materials by 2030. Could you tell us more about these initiatives? And how does all of this translate to the LEGO Group’s investment strategies and R&D to improve its sustainability efforts? TB: Currently, our bio-elements that
are made from sustainably sourced sugar cane account for 2% of our available element portfolio. We have a team of over 150 people dedicated to finding new, more sustainable materials for LEGO bricks without compromising quality or safety. We are currently piloting whether we can potentially use bio-elements more widely in the portfolio and exploring opportunities with recycled plastics. We have a team of over 150 people dedicated to finding new, more sustainable materials for LEGO bricks without compromising quality or safety. We are currently piloting whether we can potentially use bio-elements more widely in the portfolio and exploring opportunities with recycled plastics. PM: What is your approach to environmental sustainability and social responsibility? TB: We put children at the heart of everything we do, and our sustainability and social responsibility efforts aim to build a better planet for children – the future generations. PM
www.papermart.in / August-September, 2020 | 57
P•U•B•L•I•S•H•E•R I•N•D•U•S•T•R•Y
Publishing Industry: Re-strategizing to Adapt to the Pandemic
58 | www.papermart.in / August-September, 2020
P•U•B•L•I•S•H•E•R I•N•D•U•S•T•R•Y Keeping these challenges in mind, Mr. Vikas Gupta, Managing Director, Wiley India asserts: “The future of publishing will depend on how well publishers can evolve and create a solution that can go up the value chain. Publishing is an important service, which makes an author’s content reach out to the masses in the best possible way through its distribution network, which comes at a cost.” He further states, “When it comes to online content, the situation becomes even more alarming as people usually believe that online content is available for free and can be easily reproduced. All these aspects make publishing a daunting business proposition, and publishers are struggling to survive.”
As building digital infrastructure supporting resilient operations becomes a key priority due to the pandemic, the publishing houses in India are re-assessing their plans of distribution of content keeping in view the rising prominence of e-content and online learning. As we are in the middle of a pandemic outbreak, it is very difficult to estimate its long-term effects. Even though our society has been hit by several pandemics in the past, it is still quite tough to foresee the long-term economic, behavioral, or societal consequences of the ongoing pandemic. The lockdown imposed due to the pandemic has affected almost every industry in the world economy. It is no wonder that first phase of the recent lockdown particularly has posed pertinent challenges for the publishing industry. The continued closure of schools and other educational institutions due to the lockdown has dealt a blow to the textbook industry, with booksellers and publishers experiencing an unprecedented decline in their business after decades of robust growth. Evolving in Newer Directions As published in HT, according to the reports of India Book Market by Nielsen released in 2015, there were about 21,000 book retailers and about 9,000 publishers in India, out of which 8,107 published books for schools, colleges and higher educational institutions. Educational books took up about 70% of the book market in India — with the school and college books market valued at Rs. 18,600
crore and Rs. 5,600 crore respectively in 2013–14. According to the report, the K-12 books market was likely to grow at a compound annual growth rate of 19.6%, from Rs. 22,170 crore in 2014-15 to Rs. 54,190 crore by 2019-20. However, in this otherwise thriving landscape of textbook publishing in India, which is one of the major segment within the whole publishing sector, the sales of some well-known publishers dropped 50% compared to last year. Publishers were sitting on massive unsold stocks. Since the lockdown happened in March, the last-mile sales of books also suffered. Most publishers had dispatched the books to distributors or bookshops but a lot of stocks are still lying unsold with them. As reported in HT, nearly 3040% stocks were returned. Now with the approval of the National Education Policy (NEP) by the Union Cabinet, the publishers believe that it is a welcome move – ushering in an era which will bring transformational reforms in schools and higher education, with the goal to make “India a global knowledge superpower”. This will propel the demand for textbooks and journals, both at the students’ and the institutional levels. Navigating the challenges Many in the industry are of opinion that one of the major reasons for the fall in the textbook sales is also the fact that a large number of children of migrant workers in budget schools have gone back to their villages, and are unable to continue their education online.
Not so long ago, people generally preferred reading physical books over eBooks or audio books, but now considering hygiene issues there has been a significant shift in their choice in the last few months. Moreover, in the current state of things, the publishers contend that they have witnessed the online consumers to spend greater time on audio books and e-books. Sharing industry insights on the changes brought due to lockdown and pandemic, Ms. Monica Malhotra Kandhari, Managing Director, MBD Group told: “The physical print and e-content side of the publishing industry will grow side-by-side as the large population in the country means that while the demand for physical books will not wane anytime soon; however, a major thrust in the publishing industry will be on e-content generation and distribution. For instance, academic books will continue to witness high demand while easier access to technology and the internet will spur the consumption of digital content.” As we step into the postcoronavirus world, the publishers are re-thinking to find a balance between what worked before and what needs to happen to sustain well in the next normal. In this feature, Team Paper Mart interviewed two key publishing houses in India – MBD Group and Wiley India on how they are seeking to accelerate to create value-creating opportunities in the pandemic as there has been a notable rise in demand for online learning resources.
www.papermart.in / August-September, 2020 | 59
P•U•B•L•I•S•H•E•R I•N•D•U•S•T•R•Y
“
The future of publishing will depend on how well publishers can evolve and create a solution that can go up the value chain.
” Paper Mart: What is the impact of COVID-19 on the publishing industry so far? Vikas Gupta: While the pandemic has probably given more time to read more books, which should be a positive indication for the publishing industry; however, the fact is that the pandemic has hit the publishing industry just as it has impacted almost every business. The subsequent lockdown impacted the sales, printing, and production of books, thereby, pushing publishers to adapt to the evolving landscape of the publishing industry. Also, the lockdown led to the adoption of digital as a mainstream mode of teaching and learning. The universities shifted from their traditional mode of teaching and embraced online education. In order to align effective educational strategy with the rapidly changing scenario, universities are now increasingly demanding digital learning solutions which include labs, courseware, and e-books. Moreover, stay at home learning is driving the need for digital courseware. PM: What are your expectations from the Govt. with regards to support?
Mr. Vikas Gupta, Managing Director, Wiley India
60 | www.papermart.in / August-September, 2020
VG: It is fascinating to see how the pandemic has changed the status quo. Knowledge and content vetted by the experts, available to solve real-world problems has become the necessity. Research and researchers are in the spotlight, their academic journals are cited, and their editors are getting featured in media. The whole world is looking forward to researches that are being conducted on vaccine and cure of COVID-19, thus, making applied research an integral part of the economy. The need of the hour is to increase research funding to ensure quality research that will help solve the
P•U•B•L•I•S•H•E•R I•N•D•U•S•T•R•Y country’s niche problems.
PM: How things will evolve in future?
Further, the COVID relief package issued by the Government gave a much-needed boost to bringing digital learning into the mainstream. For instance, QR code enabled books, and e-Vidya portal are ambitious, yet need of the hour projects. The key challenge maybe is around its speedy and quality implementation. Currently, the government’s spending on education in India is a mere 4.6% of the GDP, slating India as 62nd in the world. The NEP policy has increased it to 6 percent of the GDP; which will also be inadequate given the scale of digitization and research focus proposed. This is where a Public-Private partnership model can emerge. The role of publishers becomes very important here – we can partner with the government to make available updated, adaptive, and enriched books and learning materials for free distribution on government channels. The cost of development, distribution, and other economic activities on the part of the publishers can be allocated in the National Education Budget. This will bring equity in education across the country by ensuring access to all sections of our population.
VG: The future of publishing will depend on how well publishers can evolve and create a solution that can go up the value chain. Publishing is an important service, which makes an author’s content reach out to the masses in the best possible way through its distribution network, which comes at a cost. Thus, going forward, publishing will transform into a framework where content is free, but the services, delivery format and learning customization that publishers will build would have a premium price.
PM: Will the NEP Policy 2020 stir back the market for the Indian book publishers? How helpful would this new policy be?
(c) Providing new business models, with the remaining at risk of losing sooner or later.
When it comes to online content, the situation becomes even more alarming as people usually believe that online content is available for free and can be easily reproduced. All these aspects make publishing a daunting business proposition, and publishers are struggling to survive. In this difficult scenario, publishers who recognize the importance of technology as an enabler will be able to succeed by: (a) Generating unique value ideas using technology, (b) Developing a viable learning ecosystem, and
VG: The publishing landscape for higher education is large and diverse in India, with a high demand for books by a large chunk of the younger population for education and skill-enhancement purposes. The academic publishing represents the diverse needs of central, state, and privately funded institutions and research bodies, thereby making it uneven across the nation. The New Education Policy will bring some fundamental changes to the current system. The aim to increase Gross Enrollment Ratio to 50% by 2035 by adding at least 3.5 crore new seats to higher education, bringing in international campuses in India, setting up universities and colleges in or near every district and making the current universities, research-focused universities, will open new opportunities for academic publishers. This will fuel the demand for books, both at the students’ and the institutional levels. Libraries will be required to expand their offerings, by not only purchasing more, but also inducting online courseware in their portfolio to support the online classrooms that the universities may adopt as mainstream. Increased focus on research will increase funding and encourage researchers to publish more academic journals. Also, Institutional restructuring and consolidation will end the fragmentation of higher education, thus, making it more uniform. www.papermart.in / August-September, 2020 | 61
P•U•B•L•I•S•H•E•R I•N•D•U•S•T•R•Y
“
The physical print and e-content side of the publishing industry will grow side-by-side as the large population in the country means that the demand for physical books will not wane anytime soon.
” Paper Mart: What is the impact of COVID-19 on the publishing industry so far? Monica Malhotra Kandhari: The outbreak of the COVID-19 pandemic and the subsequent lockdown has resulted in the closure of schools across the country. Sales of textbooks have plummeted by as much as 50 percent and the sales of reference books also have been dismal. The lack of demand has not only impacted publishing houses, but also those in ancillary services such as stockists and distributors who have to deal with a slowdown in business while their operations costs such as electricity bills, rent, water bills and other statutory costs remain the same. Ms. Monica Malhotra Kandhari, Managing Director, MBD Group
PM: What are your expectations from the Govt. with regards to support? MMK: The government can and must extend all possible support to the publishing industry for its survival. The industry is facing serious liquidity issues and we hope the government to step in to mitigate the situation. Bringing out a stringent law on intellectual property and safeguard against piracy will help the industry immensely now and, in the future, as well. A resolution for the long-standing GST-related issues due to books being GST free while input material such as paper, ink, and logistics to be subjected to GST would help the industry as it looks for recovery from the crisis.
62 | www.papermart.in / August-September, 2020
PM: Will the NEP Policy 2020 stir back the market for the Indian book publishers? How helpful would this new policy be? MMK: The multi-disciplinary approach of New Education Policy 2020 and the focus on making India a knowledge superpower bodes well for the publishing industry. It is expected that the implementation of the policy will take at least two years and due to the lack of detailed curriculum guidelines, the publishers cannot start work at the ground level. The impact of the new policy would only be visible once we are in the implementation stage and the publishing industry will be an important catalyst in the new scheme of things to achieve the milestones of NEP. Moreover, the Government should allow every stakeholder to participate in the effective implementation of NEP. PM: How things will evolve in future? MMK: The physical print and e-content side of the publishing industry will grow side-by-side as the large population in the country means that while the demand for physical books will not wane anytime soon; however, a major thrust in the publishing industry will be on e-content generation and distribution. For instance, academic books will continue to witness high demand while easier access to technology and the internet will spur the consumption of digital content.
P•U•B•L•I•S•H•E•R I•N•D•U•S•T•R•Y
www.papermart.in / August-September, 2020 | 63
I•N•D•U•S•T•R•Y T•R•E•N•D•S
The Future of Global Corrugated Board Packaging to 2025 A new study from Smithers shows that almost 171 million tonnes of containerboard was manufactured worldwide in 2019, with a value of USD 101 billion. The in-depth analysis in The Future of Global Corrugated to 2025 – shows this material was converted into over 155 million tonnes of corrugated packaging with a value of USD 165 billion of converter sales. The market in 2019 had growth of about 3% on 2018 volumes although total market value showed only a 2.2% increase due to softening raw material prices, with average prices moving downwards from USD 595/tonnes in 2018 to USD 589/tonne. The COVID-19 pandemic has had a profound impact on the world economy in 2020. In terms of corrugated consumption, there will be gains and losses. The Asia-Pacific region was affected worst, at least in the short term. Globally, in the multiple forecast scenarios drawn up by Smithers, it is predicted that the pandemic will lead to a reduction of 15–18 million tonnes of corrugated material in 2020, compared to pre-COVID projections. Forecast changes in regional apparent consumption of containerboard, 2019–25India in context
The top five containerboard producers in 2019 worldwide were International Paper, Nine Dragons, WestRock, Smurfit Kappa, and Lee & Man. Combined these accounted for just under a quarter of total world production in 2019, with one third concentrated across the ten largest suppliers. In India, the containerboard market is highly fragmented. Even the largest supplier WestRock accounts just over 5% of the domestic mill production; closely followed by two local firms – Dev Priya Industries, and Laxmi. India is currently the thirteenth largest market for corrugated consumption in the world; and the fifth largest in Asia. There remains a great deal of potential in India. Indeed the country has the highest growth prospects of all the countries analyzed in the Smithers study report. It has very low per capita consumption of corrugated packaging materials and high economic growth expectations, offering exciting prospects for corrugated suppliers. Smithers calculates that almost 1.2 million tonnes will be required in addition to the projected 2020 total in India to satisfy booming demand across multiple sectors through to 2025. From a regional perspective Asia-Pacific is already the largest world region market, with a 51% share by volume in 2019. This is up form up 47% in 2015. In 2019, North America was the second largest world region with a 20% share of corrugated, followed by Western Europe with a 14% share. Industry drivers Globally more than half of the total consumption of corrugated board packaging materials comes from non-food applications, covering markets as diverse as personal care products and automotive parts. Source: Smithers
64 | www.papermart.in / August-September, 2020
Food and beverages made up about 46% of the volume
I•N•D•U•S•T•R•Y T•R•E•N•D•S demand in 2019, with processed foods accounting for the single biggest share of total consumption at almost 30%. As in almost every sector the scale and the depth of economic disruption caused by the COVID-19 outbreak will impact corrugated converters. As an industry however packaging is fairly resilient to downturns, especially in developed markets. Some areas in particular e-commerce packaging are even benefitting in the short-term, as shops across the US and Europe are closed and online purchases rise accordingly. As, and when, the world economy returns to something approaching normalcy there are several trends that will shape the choice and use of corrugated packaging into the 2020s. Greener packaging Sustainability in packaging is a leading concern for many major brand owners and supports the wider use of corrugated formats, which are easy to recycle both in consumer and industrial channels. This has been exacerbated – in North America in particular – by China’s restrictions on imports of low-quality paper waste. In response major paper mills are increasing their capacity for recycled liner and fluting. Pratt Industries, for example, opened a new 425,000 tonnes 100% recycled containerboard mill at Wapakoneta, Ohio in 2019; and has plans for two further mills in the next six years. Norpac meanwhile has repurposed its former newsprint PM1 at Longview, Washington to run 100% recycled fibre. E-commerce Even before the shuttering of conventional retail outlets in Q1 2020, e-commerce packaging was forecasted to grow over three times faster than the market average. Responding to this, there is a push to develop more highquality printable white linerboard that is suitable for omni-channel format packaging – that can be use both in conventional retail and for e-commerce delivery. There is also scope to develop bespoke corrugated formats for e-commerce trade, combining convenience and extra
protection. Several corrugated forms now have dedicated service lines and design teams to deliver premium solutions for online businesses. Corrugated firms are also exploiting the desire for more fit-to-product packaging in e-commerce trade, including developing their own systems; examples include DS Smith’s Made2Fit concept and Box on Demand (BoD) from WestRock. Flute sizings Flute sizes have been driven down for many years, with the development of ever finer flutes providing greater opportunities for micro-flute corrugated to compete with folding carton packaging. Micro-flute board can now be found in a wide range of end-use applications from confectionery to cosmetics, and jewellery to household chemicals. Typically, microflute corrugated consists of an outer liner of cartonboard with a high-end print finish. Developments in digital printing are new allowing for standard whitetop linerboard to fulfill this role in some applications. In premium applications that require high-gloss finishes coated varnished cartonboard will still be necessary to provide the desired effect, however. Coatings developments Barrier coatings on corrugated board can enhance and extend many functional and protective properties. Many companies are innovating in this space enabling board makers to use existing equipment to create product differentiation, and are being positioned by marketing departments as greener alternatives to plastic packaging. A key consideration is not compromising the existing strong environmental credentials of paperboard by adding a polymer coating that compromises pulp recovery at endof-life. This is pushing R&D to way from conventional solutions towards more naturally derived coatings that are fully recyclable and/or biodegradable. — Mr. John Nelson, Editor, Smithers
E-magazine: emagazine.papermart.in A Bi-monthly Magazine for Pulp, Paper & Converting Industries in INDIA
Most Credible Source of Information for INDIAN
Paper Industry www.papermart.in Tulip 3P Media Pvt. Ltd.
www.papermart.in / August-September, 2020 | 65
N•E•W•S
SAPEAP: Reinventing Sourcing and Procurement “SAPEAP is a web portal wherein potential buyers can e-negotiate for their purchases on reverse auction basis, which helps them to get value for their investment. Through this platform we help our customers to increase their efficiency of procurement.” October 30, 2020 Introducing SAPEAP to Paper Mart, Ms. Indu Tyagi, CoFounder, SAPEAP, sheds light on the reverse auction: “Every industries purchases raw material and negotiate with their suppliers but the question is how big companies negotiate with their suppliers? The answer is — the negotiation is carried through online reverse auction portal, where multiple prospective suppliers bid against each other to see who is willing to offer the lowest price point for their good or service to the auction holder. Besides, e-negotiation saves up to 35% of money by increasing competition among suppliers in real time negotiations.” Speaking on what prompted the launch of SAPEAP, Ms. Tyagi told that: “Generally, reverse auction platforms are feasible for big companies as such platforms are quite expensive. So we thought to provide similar platform to mid level and even small companies at nominal fees. This platform is a revolution in itself, and there is no competitor and no one is providing services like we do. We also plan to start more than 20 offices across India by beginning of 2022. We make sure that software access is provided to the suppliers who are duly verified and have credentials in industry. Talking about company’s association with the suppliers, Ms. Tyagi told that “Under our privacy policy we do not disclose who are on board with us. No one wants to reveal that from where they are purchasing and at what rate. Currently, we are serving clients from textile, paper, steel, pharmaceuticals and other industries. Being an open platform, anyone can access
Ms. Indu Tyagi, Co-Founder, SAPEAP
the bid; however, participation can be done only through valid and unique login credentials so that no one knows who is quoting in during the auction without revealing the name of the buyer online. Our customers are aware that SAPEAP being an online platform, there is no need to meet with supplier to negotiate on pricing. Hence, in this time of COVID, online negotiation is a must for all the companies.’’
Line O Matic Introduces Ignis RR90 - Cut Size Sheeter Lineomatic brings you the Ignis RR90, the latest in cutting edge paper converting machines, which is the perfect amalgamation of affordability and quality. November 5, 2020 Based off on extensive research and consideration of the latest trends in demand within the A4 copier industry, the Ignis RR90 has been designed to offer the highest value for money as per modern-day demands. Built with both efficiency and precision in mind, with an easyto-operate central interface, the Ignis RR90 is an industrial paper converting machine that is designed to be an affordable option for entry level companies looking to enter this market segment. True to its name, deriving from the Latin word “ignis” signifying fire, this industrial paper converter is known for its flexibility, its rapidity, and its smooth functioning. The core utility of the
66 | www.papermart.in / August-September, 2020
Ignis RR90
N•E•W•S
www.papermart.in / August-September, 2020 | 67
N•E•W•S Ignis RR90 lies in its ability to directly convert large paper reels into A4 sized copier reams in a cost-effective way. The Ignis RR90 is a marvel of modern engineering, a sleek machine that is constituted of both intricate and advanced components working together in complete harmony. The central control unit with its intuitive interface allows you to synchronize the movements and capabilities of some of the most advanced components in the paper converting industry today. The fundamental components of the Ignis RR90 include twin
unwind reel stations, decurling unit, slitting unit, syncro rotary cutting unit, conveyor unit, collating unit, robot conveyor, and a ream wrapping unit. For those firms that are on the quest for a high level of automation in their paper converting needs and also desire a high quality output, the Ignis RR90 is the most cost-effective and suitable option at their disposal. As per our existing customers, some of the most amazing benefits of the Ignis RR90 include the high-end quality of wrapping and the degree of paper cutting precision that it provides, which is unrivalled at this price range.
Schaeffler India Launches OPTIME for Paper and Cement Industry OPTIME makes condition monitoring easy, cost-efficient and highly scalable for the first time. In this way, mills can tackle unplanned downtimes holistically. October 14, 2020 Leading industrial and automotive supplier Schaeffler India has launched a new product called ‘OPTIME’. It is an efficient and easy-to-use low-cost solution designed specifically for comprehensive condition monitoring of all process-critical assets across entire machine and equipments. Schaeffler OPTIME provides automated condition monitoring at a costeffective but efficient manner making it very convenient for maintenance personnel and facility operators. The India launch of OPTIME is a part of the overall launch in the entire Asia Pacific region. OPTIME is an easily scalable system that consists essentially of wireless, battery-powered vibration sensors, a gateway, and an app to visualize the resulting analysis data. The data captured by the sensors are analyzed using specially developed algorithms that draw on Schaeffler’s technical expertise, which is developed and refined over many decades. OPTIME provides several weeks’ early warning of damage to machine components such as electric motors, fans, and pumps. It also provides early warning of imbalances, misalignments, and knocking. Introducing the product Mr. Harsha Kadam, CEO, Schaeffler India and President Industrial Business, said, “The impact of unplanned downtimes is far more damaging than revenues alone, and brings forth multiple challenges in any manufacturing or processing unit. For cost reasons, permanently installed continuous condition monitoring systems are typically used only for production machines that are directly process-critical. Therefore, in process and automation industries, it is not uncommon for up to 95 percent of all assets in a production facility to be either totally unmonitored or monitored only periodically by means of route-based, manual measurements. With Schaeffler OPTIME, however, comprehensive and automated condition monitoring is now a cost-effective proposition for maintenance personnel and facility operators.” He further added that, “With OPTIME, in-house maintenance crews and external service contractors receive specific recommendations on the remedial steps required, so they can easily plan their maintenance work, manpower requirements, and spare parts procurement in a timely and cost-efficient manner.” OPTIME can be installed and initial operation carried out without any prior condition monitoring expertise, and several hundred measuring points can easily be set up in the space of a
68 | www.papermart.in / August-September, 2020
OPTIME - Plug Play Predict
single day. The vibration sensors are attached to the monitored assets by means of screws or adhesive, and are activated by the accompanying app, which connects to them via near-field communication (NFC). All installed sensors communicate autonomously with each other and the gateway, thereby forming a dedicated mesh network that ranks among the most reliable and energy-efficient types of IoT networks in use in industry today. The sensors in the mesh network transmit machine KPI data and raw vibration and temperature data via the gateway to the Schaeffler IoT Hub. The hub analyzes the data, and the results are displayed in the app, which supports a very wide range of end devices commonly used by maintenance teams and plant operators. Alternatively, the analysis results can be made available for integration into the customer’s own IT environment via a REST API. The app provided along with Schaeffler OPTIME presents trends in graph form and visualizes the severity of incidents using traffic light colors, alarm states, and other information. Assets can be grouped according to users’ requirements, and their condition can be presented in a range of user groupspecific views. OPTIME can yield cost savings of around 50 percent compared with monthly offline measurements made using hand-held devices. It also provides better-quality monitoring than most wireless online CMS systems thanks to its complex, algorithm-based analytics. Moreover, OPTIME can be used for a multitude of assets for which condition monitoring was previously not commercially viable, which makes it the first solution capable of providing an overview of machine states that is truly comprehensive and encompasses all subsystems and auxiliary assets. This is important, because the automated condition monitoring of all assets is fundamental to the reliable prevention of unplanned machine and plant shutdowns.
N•E•W•S
www.papermart.in / August-September, 2020 | 69
N•E•W•S
S.K. Paper Mills to Setup 65 TPD MG Poster & Tissue Paper Mill With an investment of INR 30-35 crores, the company will setup the MG Poster and Tissue Paper Mill in the recently acquired 9 acres of land in Jolly Road at Muzaffarnagar. November 2, 2020 The envisaged paper mill is being set up on 9 acres (22.5 bigha) of land in Jolly Road at Muzaffarnagar (Uttar Pradesh). Mr. Sakar Gupta, Managing Director, S.K. Paper Mills Pvt. Ltd. informed Paper Mart, “The company will be producing Soft Tissue, Hard Tissue, High BF Kraft and all kinds of Poster (white and colored) in the range of 18 GSM to 150 GSM. The installed capacity thereof will be 65 TPD. The commercial production commencement is scheduled likely in May, 2021.” The ordered paper machine has a deckle size of 4.2 meter and is designed to run at a speed of 500 MPM. The machine will be procured from Peer Paper Machines Pvt. Ltd., Pulp Mill from Parason Machinery India Pvt. Ltd. and MG from SPM ENGMECH (INDIA) Pvt. Ltd. All these suppliers are well known and pioneers in their respective fields. The raw material used for the project is 100% waste paper and will be sourced from domestic and overseas suppliers. The estimated cost of the project is INR 30-35 crores. The envisaged paper mill is not only a commercial project but also a dream to usher in a new era of packaging products and base paper for different kinds of coating industries.
Mr. Sakar Gupta, Managing Director, S.K. Paper Mills Pvt. Ltd.
Mahaveer Paper Mill Starts 30 TPD Writing & Printing Paper Plant in Odisha Situated at Titilagarh in Balangir district of Odisha, Mahaveer Paper Mill Pvt. Ltd. took over an old paper mill - Spaa Straw Board Industries Pvt. Ltd. Mr. Anil Modi & Mr. Anuj Modi, Directors of the MPMPL revived the production in December 2019. November 4, 2020 As informed to Paper Mart, Mahaveer Paper Mill has commenced the production on its 900 TPM writing & printing paper plant keeping in view with the current product portfolio prevailing in the domestic market. The company manufactures cream wove paper, ledger paper, color paper and maplitho in the range of 44 to 90 GSM. The raw material used for the production is 100% waste paper sourced from both domestic and overseas suppliers. The mill has a de-inking pulping system with a capacity of 45 MT per day. The deckle size of paper machine is 2100 mm and is designed to run at a speed of 250 MPM. The mill has a 6 TPH FBC boiler with steam return condensate system. Mahaveer Paper Mill has its market footprint in the states of Odisha, Jharkhand, Bihar, Chhattisgarh and West Bengal. To expand the product portfolio, mill is under going through modification for kraft paper and newsprint grade paper.
70 | www.papermart.in / August-September, 2020
N•E•W•S
We Take Care of
Our Strength
Content Strategy & Creation
Digital Presence
Market Insight
Database Management
Wide Readership
Visual Appeal
Industry Networking
Advertise with us E-magazine: www.papermart.in/emagazine Website: www.papermart.in www.papermart.in / August-September, 2020 | 71
N•E•W•S
ITC-PSPD Orders New Evaporation Plant from Andritz for Bhadrachalam Unit This investment is part of ITC-PSPD’s recovery plant modernization project to further strengthen its market position in the paperboard and specialty paper segment. November 4, 2020 Andritz has received an order from ITC Paperboards and Specialty Papers Division (ITC-PSPD) to supply a new evaporation plant for its Bhadrachalam unit located in Telangana, India. Andritz will supply a new 7-effect evaporation plant on EPC basis with a capacity of 390 t/h that will concentrate kraft black liquor to a final dry solids content of 75%. The plant will be the largest in India and have the capability to improve the quality of condensate from the existing mill so that it can be re-used effectively in the mill and also to reduce water consumption. Andritz’s lamella technology in the evaporators ensures the desired steam economy at all times, reduces energy consumption by circulation pumps, as well as providing higher black liquor concentration and stability, thus leading
Andritz Evaporation Plant
to increased and stabilized power production in the recovery boiler. The technology also delivers optimized vapor condensate quality that contributes towards a reduction in the mill’s operating costs. In addition, fewer and shorter washing cycles will enhance overall availability.
Trident Group has Partnered with Pravasi Rojgar Committed to Onboard 3000 members This initiative is in line with the company’s corporate philosophy of integrating CSR. August 21, 2020 The Trident Group has partnered with “Pravasi Rojgar” and has committed to onboard 3000 members in different roles across Trident in coming months. Padmashri, Mr. Rajinder Gupta, Chairman, Trident Group confesses that his passion in life is to add value in the life of the people. We are proud of being an Indian grown company. We wish to act as a catalyst in prospering the lives of the people. The initiative is in line with corporate philosophy of integrating Corporate Social Responsibility (CSR) into Trident values, culture, operation and business decisions at all levels of the organization. Being a responsible manufacturer, Trident has a value system of giving back to society, improving life of the people and the surrounding environment.
Mr. Rajinder Gupta, Founder and Chairman, Trident Group
72 | www.papermart.in / August-September, 2020
N•E•W•S
Valmet to Invest in Filter Fabric Manufacturing in India The investment includes manufacturing equipment for filter fabric production. The new unit will start operation in the second quarter of 2021. October 28, 2020 Valmet has decided to invest in filter fabric manufacturing in Pune, India in order to better serve its customers and improve delivery times of filter fabrics to the Asia Pacific and Middle East areas. “This investment gives us the necessary assets to further develop our services close to customers and strengthen our position in the market. It also ensures our capacity for the coming years to deliver filter fabrics that respond to customer needs for maximized reliability and optimized performance of their production process,” says Tero Kokko, Vice President, Fabrics Business Unit, Valmet.
Valmet to invest in filter fabric manufacturing
Coca-Cola Reveals First Paper Bottle Prototype The company is developing new packaging technology that will eventually create a 100% paper bottle. October 30, 2020 In partnership with Paboco and the three other companies in the Paboco Pioneer Community, Coca-Cola has revealed a first-generation prototype of its paper bottle. The company has not yet realized its ultimate goal of creating a 100% paper-based bottle, as the structure of the prototype consists of a paper shell with a plastic closure and a plastic liner inside. While the plastic used is 100% recycled and can be recycled again after use, the company aims to eventually create a paper bottle that can be recycled like any paper. Coca-Cola says that the next step is to find a solution to create a bottle without the plastic liner. “Our vision is to create a paper bottle that can be recycled like any other type of paper, and this prototype is the first step on the way to achieving this. A paper bottle opens up a whole new world of packaging possibilities, and we are convinced that paper packaging has a role to play in the future,” says Stijn Franssen, EMEA R&D packaging innovation manager at CocaCola, who is working on the project. Just like other types of packaging, a paper bottle of the future must adhere to the same high safety and quality standards for food and drink packaging that currently apply. Stijn and this team are putting the bottle through testing in a lab to see how it performs in the refrigerator, how strong it is, and how well it protects the beverage inside.
Paper Bottle Prototype
www.papermart.in / August-September, 2020 | 73
N•E•W•S
Nestlé Launches Maggi Organic Bouillon Cubes in Recyclable Paper Wrapper Maggi has broken new ground by becoming the first major brand to use recyclable paper packaging to wrap individual bouillon cubes, for its organic range in France. This is the latest result of an innovation drive to use more paper packaging for Nestlé products. September 7, 2020 The new solution is a coated paper that is recyclable through the paper stream in France. Until now, the bouillon cubes have been wrapped in a multi-layer laminate that includes aluminum. Agnes Lalanne, Global Category Lead for Cooking Aids at Nestlé, said: “We want to provide both healthy and more sustainable options. That’s why we’re happy to bring recyclable paper packaging to a favorite like these Maggi organic bouillon cubes.” The paper used for the wrapper is from sustainable sources – pulp and paper mills certified by the Forest Stewardship Council (FSC) and The Program for the Endorsement of Forest Certification – and its development marks another step in Nestlé’s commitment to make all its packaging recyclable or reusable by 2025, as the company works towards a waste-free future.
Maggi bouillon cubes in recyclable paper wrapper
Ahead of the launch, the team also worked to refurbish and upgrade existing packaging machines, to allow the new paper wrapping to run on them.
Stora Enso to Build Pilot Plant for Bio-Based Packaging Foam Cellufoam™ by Stora Enso is a sustainable packaging material and it further increases Stora Enso’s opportunities to replace fossil-based materials with renewable and recyclable materials. August 26, 2020 Stora Enso will build a pilot facility for producing Cellufoam™ by Stora Enso, a lightweight, fiber-based foam material for protective packaging and cushioning. Bio-based foams are renewable and recyclable and can be used in packaging, for example, to replace oil-based polymer foams which are widely used today. The pilot plant will be located at Stora Enso’s Fors Mill in Sweden. Cellufoam™ by Stora Enso is a sustainable packaging material and it further increases Stora Enso’s opportunities to replace fossil-based materials with renewable and recyclable materials. The initial target application for Cellufoam™ will be the protective packaging of fragile products, for example in consumer electronics. Bio-based foams also have the potential to replace polymeric foams in a range of markets and applications where the demand for sustainable materials is increasing, such as sports equipment, thermal insulation in shipments and as a growth medium in soil-free farming, among other areas.
74 | www.papermart.in / August-September, 2020
Cellufoam
N•E•W•S Stora Enso’s pilot aims to evaluate and validate Cellufoam™ as a packaging foam in customer tests and to further develop the production process. The new pilot plant will be part of Stora Enso’s Biomaterials division.
The design and engineering of the pilot facility will start immediately. It is estimated that the plant will be ready in the fourth quarter of 2021. Decisions about commercialisation will follow, after evaluating the results of the pilot-scale production.
Georgia-Pacific Recycled Paper Mills Open Opportunities for Paper Cup Recycling The development follows two years of partnership with the Foodservice Packaging Institute (FPI) and collaboration with the NextGen Consortium, a global initiative led by Closed Loop Partners with founding partners Starbucks and McDonald’s, to help open opportunities for paper cup recycling. September 14, 2020 Georgia-Pacific has announced that it is now accepting mixed paper bales that contain single-use polyethylene (PE)-coated paper cups at its recycled paper mills in Green Bay, Wisconsin, and Muskogee, Oklahoma. PE coatings, along with any remaining liquid and food left behind from use, have historically left single-use paper cups out of the recovery and recycling process. GP, though, has proven through its extensive re-pulping trials that the Green Bay and Muskogee mills can effectively recapture valuable cup fiber from paper cups while screening out PE-coatings and reuse the fiber to make toilet tissue, napkins and paper towels. Beyond its current repulping efforts, GP is also collaborating with the NextGen Consortium to trial at its mills next generation paper cups that have replaced the PE-coating with materials that can be recycled and/or composted. As founding partners of the NextGen Consortium and strong advocates of reducing single-use paper cup waste, McDonald’s and Starbucks are supportive of ongoing collaboration with GP and encouraged by the company’s current re-repulping efforts.
Georgia-Pacific’s Green Bay, Wisconsin, and Muskogee, Oklahoma, recycled paper mills are now accepting mixed paper bales with PE-coated paper cups
With its Green Bay and Muskogee mills now engaged, GP is working with FPI to expand and accelerate single-use PEcoated paper cup acceptance in curbside recycling programs in an effort to increase the number of households that can recycle the paper cups.
Sumitomo SHI FW’s CFB Boiler Modernization Project to Cut 30% CO2 Emissions in Sappi’s Mill October 22, 2020 SFW will design, supply and erect the project, which includes modifications to the lower furnace, new heat shift system; biomass feeding system, bottom ash extraction system, and emissions control system, as well as dismantling and commissioning. The modernization will allow the plant to completely shift from coal to multiple sustainable and renewable fuels. The new emissions control system include bag filters and selective non-catalytic reduction (SNCR), which will ensure the plant meets the newest Best Available Technologies (BAT) standards, especially regarding dust and NOx emissions.
The project will be completed at the end of 2021.
www.papermart.in / August-September, 2020 | 75
N•E•W•S
Mondi Launches Water-Resistant Paper Bags for Cement Industry Applying Mondi’s customer-centric EcoSolutions approach, Mondi focused on Adelaide Brighton Cement and Pope Packaging’s goal to provide a more functional and sustainable packaging solution. October 2, 2020 Mondi, a leading global packaging and paper manufacturer, has partnered with Adelaide Brighton Cement and Pope Packaging on the development of a new water-resistant paper bag called ‘Rain Barrier,’ made out of Mondi’s Advantage Protect White sack kraft paper, for the Australian construction market. Standout characteristics include its water repellent surface and high tensile strength in a wet environment. While a standard paper bag absorbs water, the qualities of the Rain Barrier bag, keeps water from seeping in, as it stays on the surface where it evaporates. The paper itself is rain resistant for up to six hours and can resist water ingress for up to five full days when stored in damp conditions.
Rain Barrier Bag
Stora Enso and Tingstad Launch Unique Formed Fiber Food Service Bowls to Replace Plastics PureFiber™ by Stora Enso is a new selection of formed fiber products helping customers to replace plastics. October 13, 2020 Stora Enso is introducing its new eco-friendly take-away bowls for food service packaging, PureFiber™ by Stora Enso. The products are free from plastic and PFAS and are designed to help customers replace plastic on-the-go food packaging. The bowls are being brought to market together with the wholesale company Tingstad. The PureFiber™ product range will expand to other food and consumer goods applications. Stora Enso’s formed fiber products are designed for circularity, meaning that they are renewable, recyclable and biodegradable. The PureFiber™ product line enables a carbon footprint that is approximately 75% lower compared to alternative product materials such as plastic or bagasse. The unique formed fiber technology allows the products to be produced without plastic and PFAS, bringing a sustainable alternative with strong user-qualities to the market. PureFiber™ products are produced in Stora Ensos Hylte Mill in Sweden and made of natural wood fibres from sustainably managed forests. Potential applications also include non-food items to replace plastic consumables in agriculture, electronics and consumer and industrial goods packaging.
PureFiber™ by Stora Enso
76 | www.papermart.in / August-September, 2020
N•E•W•S
Lecta to Purchase Avery Dennison Offset Sheets Business in EMENA Region Lecta will bring to current Avery Dennison’s customers in the EMENA markets its extensive knowledge in the manufacture of self-adhesive materials with a strong specialization in sheets and facestock materials, as well as its extensive experience in commercial management and service to distributors. October 14, 2020 Lecta has reached an agreement for the acquisition of Avery Dennison Offset Sheets business in the Europe - Middle East - North Africa (EMENA) region. The transaction is subject to competition approval from the German Federal Cartel Office. Lecta taking over the manufacture and sale of Avery Dennison’s portfolio of FASSON™ and JAC™ branded self-adhesive papers and films in EMENA. Lecta will manufacture these under a special limited licensing agreement with Avery Dennison, keeping the FASSON™ and JAC™ brands available through the existing network of distributors. This acquisition is fully aligned with the Company’s transformation process and its reorientation towards the specialty markets. Lecta’s self-adhesive materials production plant has received large investments in recent years that place it in the state of the art in both production technology and process automation, which guarantees high quality standards for our customers.
Avery Dennison Building
Valmet Strengthens its Business by Acquiring PMP Group The enterprise value of the acquisition is approximately EUR 64 million, plus a conditional and capped earn-out component. October 15, 2020 Valmet has completed the acquisition of PMP Group in Poland following the agreement that was announced on September 11. PMP Group is a provider of technologies and services for the paper industry. The acquired business becomes a part of Valmet’s Paper business line. PMP Group supplies process technologies and services for tissue, board and paper machines globally, focusing on small and medium-sized tissue machines and board and paper machine rebuilds. The net sales of the company were approximately EUR 70 million in the fiscal year 2019. The company employs about 650 people in Poland, China, USA and Italy. PMP will be included in Valmet’s financial reporting for the first time in Valmet’s fourth quarter financial reporting 2020.
Valmet has completed the acquisition of PMP Group
www.papermart.in / August-September, 2020 | 77
N•E•W•S
Stora Enso Invests in Forshaga to Develop Sustainable Barrier Solutions Stora Enso is making an investment in dispersion barrier technology at its Forshaga site in Sweden, as a step in its innovation agenda. September 15, 2020 The investment of approximately EUR 10 million enables the development and production of paperboard with barrier properties that are easier to handle in a recycling process, have a lower carbon footprint and can be compostable in industrial facilities. The new equipment is expected to come into use during the second quarter of 2021. Stora Enso Forshaga manufactures and develops barrier solutions that are required in certain packaging, for instance to protect against liquid, moisture, oxygen or fat. Liquid packaging, beverage cups and certain food packaging are some of the products that have a barrier which serves to protect the packaged product, while also ensuring that the packaging maintains its user-qualities. The investment in new dispersion technology aims to achieve the desired barrier properties in a more sustainable way.
Stora Enso is making an investment in dispersion barrier technology
BTG Supplies its 200th Single Point Kappa Analyzer to Oji Group The BTG Single Point Kappa offers the unique capability to measure kappa number directly at the installation point. September 2, 2020 The 200th BTG Single Point Kappa Analyzer (SPK) was supplied to the Oji Group, one of the leading manufacturers of paper and paperboard in the world, headquartered in Japan. Oji was among the early adopters of the SPK, and this latest order for Oji Materia in Japan is a key element in replacing an existing multi-point kappa analyzer system. The BTG Single Point Kappa offers the unique capability to measure kappa number directly at the installation point, rather than in a lab or through a traditional centralized analyzer. This allows a higher frequency of analyses and no need to have a dedicated sample line. SPK facilitates improved process control and operational stability in the fiberline. The first version of SPK was released in 2014, as a breakthrough innovation for Kappa control. The unit has been improved for higher Kappa applications, enhanced reliability and its capability extended to Hexuronic acid measurement. SPK is a key part of an integrated solution, optimizing the overall pulp quality and cost in the fiberline, including connection to advanced process controls and remote accessibility.
78 | www.papermart.in / August-September, 2020
BTG Single Point Kappa Analyzer
N•E•W•S
Voith Adds New Tool for Remote Video Support to its Digital Service Portfolio With OnCall.Video tool, Voith is playing an important role in making processes even more efficient and sustainable through the use of digital solutions. September 22, 2020 SFW will design, supply and erect the project, which includes Voith has added a new tool for remote video support to its service portfolio, offering customers access to expert support at any time and from any location. OnCall.Video enables fast problem-solving and cuts downtimes, resulting in improved machine availability and productivity. Thanks to the audio-visual communication system OnCall. Video, customers worldwide can draw on Voith expertise via an internet-based video collaboration platform at any time and from any location. Using OnCall.Video, the Voith specialist can see in real time exactly what the customer or operator is seeing at the production facility. In addition to recommending action and documentation, important information can be quickly conveyed to staff on site to provide an optimum level of support. The digital solution is device-independent, so any device can be used for communication purposes. To perform servicing work with the machine still running, the technician can also wear industrial-grade smart data glasses that allow optimum
Even when travel options are limited, OnCall.Video provides fast and reliable support to ensure on-time delivery and commissioning.
communication with the Voith expert thanks to integrated voice control and active noise cancellation. Moreover, the smart glasses allow operators to keep their hands free, are splash-proof and dust-tight, and are compatible with the necessary PPE.
Domtar Signs Agreement With Voith for Kingsport Mill Conversion to Containerboard Voith will provide Domtar with equipment and technical services to convert the paper machine at its Kingsport, Tennessee. November 2, 2020 Domtar Corporation has signed an agreement with Voith to provide equipment and technical services to convert the paper machine at its Kingsport, Tennessee, mill to produce recycled containerboard including high-performance lightweight packaging grades, as well as industry standard grades. In addition to being a full-line supplier to the paper industry, Voith is also recognized as a leader in the containerboard machinery business. The company will play an important part in Domtar’s entry into the containerboard market by helping build one of the most modern recycled containerboard machines in the world, able to set industry benchmarks in recycled containerboard strength and convertibility. In August, Domtar also signed an agreement with Voith to provide a complete recycled stock preparation system for the Kingsport Mill including water, sludge and reject handling systems which will maximize both efficiency and quality.
The mill’s conversion to is expected to be complete in 2022.
Once complete, the Kingsport Mill will become North America’s premier lightweight containerboard facility – able to produce and market about 600,000 tons of high-quality recycled linerboard and corrugated medium annually. That level of capacity will make Kingsport the second-largest recycled containerboard mill in North America. www.papermart.in / August-September, 2020 | 79
N•E•W•S
Valmet to Supply OptiConcept M Containerboard Making Line to Shanying Paper in China The order is included in Valmet’s orders received of the second half 2020. The value of the order will not be disclosed. October 19, 2020 Valmet will supply a new OptiConcept M containerboard making line with extensive package of automation to Shanying Paper, Guangdong at its Zhaoqing mill in China. The new board making line (PM 52) will produce kraft top liner grades and expand Shanying Paper’s business to Guangdong area. Valmet’s delivery for PM 52 will include a high-speed container board making line from broke collection to reel and winders. OptiFlo Foudrinier headboxes, OptiFormer Multi forming section and OptiPress Linear press section to produce highquality base board are also included, followed by an OptiSizer Film sizer, an OptiCalender Hard calender, and OptiReel Linear reel combined with transfer rails, an OptiCart Stream parent roll cart, one OptiWin Drum two-drum winder and one OptiWin Drum two-drum base winder.
Valmet to Supply OptiConcept M Containerboard Making Line to Shanying Paper in China
The wide automation package includes Valmet DNA automation system for process and drive controls as well as runnability and condition monitoring and Valmet IQ
The 9,300-mm-wide (wire) board machine will produce kraft top liner grades. The design speed of the machine will be 1,200 m/min and the daily capacity is approximately 1,920 tonnes.
quality management solution. The delivery will also include comprehensive Valmet Paper Machine Clothing, spare parts and consumables packages.
REPLUS TISSUE — A New Company is Born REPLUS TISSUE is not just services and products: it is designs strategy; it understands customer needs and a creative vision of effective technical solutions. November 3, 2020 Designing tissue plants that constitute effective answers to customers’ specific needs, looking ahead towards a sustainable future with a low environmental impact; combining together energy, mechanics, automation and the environment by building something that was unimaginable before is possible today. REPLUS TISSUE’s greatest strength is the continuous improvement of efficiency in every part of the process, in an increasingly competitive market where it has chosen to distinguish itself by listening to the needs of customers and innovating in the realm of environmental sustainability. “We express the view about our company and our ability to create PLUS through 4 words that best characterize us: Purpose, Line, Unity, and Strategy. Today we propose the first, Purpose.”
REPLUS TISSUE
PURPOSE – The strength of know-how, the flexibility of strategic solutions
Strong of its long-standing experience in mechanics, aerothermia, automation and electrification, REPLUS TISSUE today spans from the building of plants, designed based on the specific needs of every individual customer, to technical and process solutions in complete synergy with automation, that move the boundaries of technology and of research forward, opening up new roads to tread.
A new company is born, built on solid foundations of longstanding experience and expertise in mechanics, in the process, and in energy savings, for the design and manufacture of plants for the production of tissue paper. REPLUS TISSUE is not just services and products: it is designs strategy; it understands customer needs and a creative vision of effective technical solutions.
REPLUS TISSUE is new, but its history comes from longstanding tradition: from the abilities of Itangelo Spagnoli and Andrea Poleschi of EIL, that since 1980 has been offering the field of paper technological innovation and technical support in the electrical domain; and from the thirty-year experience of the Michelini family in the field of technology for tissue machines and plants.
80 | www.papermart.in / August-September, 2020
N•E•W•S
Kadant Fiberline China Successfully Starts up OCC System at Shanying Mill With this project, Shanying once again affirmed the long-term cooperation between Shanying and Kadant Fiberline China, which has already supplied several complete new lines for its various other paper machines and rebuilt several OCC systems for Shanying. October 22, 2020 Kadant Fiberline (China) Co. Ltd., a subsidiary of Kadant Inc., has announced that it has successfully started up the OCC system at Shanying International’s Jingzhou mill. The new line is equipped with a Kadant recycled fiber processing system and an approach flow system with a design capacity of 400,000 tons per year. Shanying uses domestic recovered paper as raw material and manufactures 60 to 110 GSM corrugating base paper from the finished pulp. The innovative technologies and equipment supplied by Kadant Fiberline China enable excellent stock quality and yield significant savings in energy consumption. Dubbed PM23, the paper machine features a trim width of 7.8 m and a design speed of 1,300 MPM. The OCC line features pulping loop automation, an automated grapple hoist, ragger, and rag rope cutter. The new line is designed to: •
Improve productivity
•
Provide the mill with modern pulping operations and controls
Representational image
•
Use encoders for absolute positioning
•
Permit full DCS access to all parameters, functions, and alarms
The successful business cooperation as well as the excellent performance of recently installed technologies were the decisive criteria that persuaded Shanying to trust Kadant Fiberline China once again.
BTG Enhances its Consistency Measurement Portfolio BTG is adding a microwave transmitter to its leading consistency measurement portfolio, a technology previously supplied by Voith Paper. October 7, 2020 BTG continues to lead the global consistency market and this latest addition “further strengthens our ability to provide the best technologies to support our customers’ needs” says Dan Smith, Global Business Director for BTG’s Process Solutions Business. With this addition, BTG offers now all consistency measurement technologies, allowing experts to provide the best possible solution to any customer. Consistency measurement is vital to the papermaking process including process stability, raw material costs and final product quality. BTG Group is a multinational provider of integrated, highly specialized process solutions for the global pulp and paper
BTG adds microwave transmitter to its leading consistency measurement portfolio
industry. BTG is committed to helping its customers achieve significant, sustainable gains in business performance. www.papermart.in / August-September, 2020 | 81
N•E•W•S
Progroup Successfully Commissions Packaging Paper Machine Propapier PM 3 at its Sandersdorf-Brehna Facility Voith has delivered the entire production line including a BlueLine stock preparation with the new IntensaDrum Duo drum pulper, which can process almost 3,000 tons of recovered paper a day. August 31, 2020 German paper manufacturer Progroup AG has successfully commissioned the PM 3, one of the most modern packaging paper machines in the world, at the company’s SandersdorfBrehna facility in Saxony-Anhalt. The PM 3 is set to produce 750,000 tons of testliner and corrugated medium annually. A comprehensive sustainability concept ensures the least possible consumption of resources. Thanks to its exceptional flexibility and the close consultation between all project participants, the companies managed to complete the PM 3 within the original schedule despite the restrictions imposed by the coronavirus pandemic. Voith has delivered the entire production line including a BlueLine stock preparation with the new IntensaDrum Duo drum pulper, which can process almost 3,000 tons of recovered paper a day. The XcelLine paper machine has a wire width of 10,000 mm and an operating speed of 1,600 m/min. The TwinDrive double unwind also included in the scope of supply increases winder capacity by up to 20 percent and allows automated full reel changes. It is complemented by the high-performance winder VariFlex Performance. The scope
The PM 3 in Sandersdorf-Brehna is setting new benchmarks for efficiency and sustainability.
of supply also includes the process air and hall ventilation systems. Based on a long and successful cooperation, Voith also received a comprehensive startup clothing package for all sections of the paper machine. Other key innovations include the closed water loop that Voith developed in collaboration with Progroup.
Toscotec Starts up Two AHEAD 2.0L Tissue Lines at Sofidel America In spite of the Covid-19 pandemic and the challenges it posed, Toscotec and Sofidel went the extra mile and managed to successfully complete the project in record time. October 7, 2020 Two Toscotec-supplied AHEAD 2.0L tissue machines came online at Sofidel America’s mill in Inola, Oklahoma. Shortly after start-up, the two lines met Sofidel’s quality standards, and have been running at high operation efficiency, producing premium quality tissue. Toscotec delivered a turnkey plant including two AHEAD 2.0L machines of 5500 mm sheet trim width, 2000 m/min operating speed, each producing 60,000 tons/year. These machines are equipped with TT SYD Steel Yankee Dryer and high-efficiency TT Hoods, designed for a high level of energy recovery. The supply also included the stock preparation system, Toscotec’s patented TT SAF (Short Approach Flow), the DCS and QCS, as well as the dust and mist removal systems. Toscotec also supplied the boiler plant, the compressed air station, the bridge crane, the shaft puller, the roll handling and wrapping systems, the chemical preparation system, the hall ventilation system, and the water treatment plants.
82 | www.papermart.in / August-September, 2020
Toscotec starts up two AHEAD 2.0L tissue lines at Sofidel America.
Sofidel was provided with a comprehensive service package including the detailed mill engineering according to US codes and standards, the construction management, the plant and the machines erection, training, commissioning, and start-up supervision.
N•E•W•S
China’s Guangxi Sun Paper Orders Two Tissue Machines from ANDRITZ The provider of equipments and services for the production of all types of paper has already provided two tissue production lines to Guangxi Sun Paper for its production site in Shandong Province. October 30, 2020 ANDRITZ has received an order from Guangxi Sun Paper to supply two tissue machines for its new mill in Beihai City, Guangxi Province, China. Start-up is planned for 2021. The ANDRITZ tissue machines are of the type PrimeLineTM W 2000, with a design speed of 2,000 m/min and a working width of 5.65 m. They are equipped with a large suction press roll, an 18 ft. PrimeDry Steel Yankee with head insulation, and a re-evaporation system, thus enabling energy savings. The scope of supply also includes FibreSolve FSV pulpers, the paper machine approach flow systems, broke handling and fiber recovery, and automation systems (QCS, DCS).
This order confirms ANDRITZ’s strong market position as one of the leading suppliers of machines and systems to the Chinese tissue industry.
In July 2019, Sun Paper established a wholly owned subsidiary – Guangxi Sun Paper – to build an integrated pulp and paper mill in Beihai. For this mill, ANDRITZ was awarded the supply
of pulp dewatering and white liquor plant technologies, key process equipment, and a chemi-thermo-mechanical pulping system in June 2020.
Turkey-based Modern Karton Orders Extensive Paper Machine Grade Conversion Rebuild From Valmet The order is included in Valmet’s orders received of the third quarter 2020. The value of the order will not be disclosed. October 14, 2020 Valmet will supply an extensive paper machine grade conversion rebuild and a wide scope of automation to Modern Karton Sanayii Ve Ticaret at its Tekirdağ Mill in Turkey. In the project, paper machine PM 3 which is currently producing recycled containerboard, will be rebuilt to produce high quality coated containerboard grades. The start-up of the rebuilt paper machine is scheduled for the beginning of 2022. Valmet’s grade conversion delivery will include modifications in the existing stock preparation line and paper machine. The scope includes broke collection system, white water system and modifications to the approach flow system. The delivery in the existing paper machine will include three new OptiFlo Foudrinier headboxes, modifications to forming, press, predrying and sizing sections. The delivery will also include a completely new coating section with OptiCoat Layer curtain coating station, OptiCoat Jet blade coating station, a coating color preparation system, supply systems for both coating stations, an OptiCalender Soft calender and an OptiReel Linear center-driven reel. The delivery will also include rebuilding of the existing air systems with e.g. new open hood, heat recovery system and OptiDry Coat air dying units. The delivery will be
The value of an order of this type is typically around EUR 40-50 million.
complemented with an automation package including machine control, quality management, condition monitoring systems and retention measurement. In addition to the onsite support, the start-up and the further optimization of the rebuilt machine will be supported remotely from Valmet Performance Center. The 5,600-mm wide (wire) containerboard machine PM 3 will produce recycled white-top testliner, coated white top testliner, recycled fluting and testliner grades with a basis weight range of 105-225 g/m2 and design speed of 1,300 m/ min. www.papermart.in / August-September, 2020 | 83
N•E•W•S
PAPER MART
A Bi-monthly Magazine for PULP, PAPER & CONVERTING INDUSTRIES in INDIA
Event Calendar 8-10, April 2021
Paperex South India Chennai, India southindia.paperex.in 25-28, April 2021
TAPPICon
Atlanta, USA www.papercon.org 16-18, June 2021
Tissue & Paper Bangkok
Bangkok, Thailand www.tissueworld.com/bangkok 29-29, August 2021
Pack Plus
New Delhi, India www.packplus.in
2-4, September 2021
India Corr Expo
* Due to COVID-19 event status could change. Please check with the organizers before visiting.
Greter Noida, India www.indiacorrexpo.com 21-23, September 2021
Tissue World
Dusseldorf, Germany www.tissueworld.com 13-15, October 2021
MIAC
Lucca, Italy www.miac.info/en 6-9, December 2021
Paperex
New Delhi, India www.paperex-expo.com
Aug-Sep, 2020
Vol.: 21 / No.: 03
Editor & Publisher Parveen Kumar Jain – pkj@tulip3pmedia.in Associate Editor Geetika Jain – gjain@papermart.in Editorial Team Laique Khan – desk2@tulip3pmedia.in Soumya Ojha – desk3@tulip3pmedia.in Graphic Designer Ravi Thakur – ravithakur@tulip3pmedia.in Advertising & Marketing Puneet Dua – mktg@papermart.in Support Team Kushagra Mehrotra Sandeep Kumar Rahul Kumar admin@tulip3pmedia.in Chief Executive Officer Priyank Jain pj@tulip3pmedia.in Editorial & Publisher's Office : Paper Mart, Tulip 3P Media Pvt. Ltd. 218, Sanjay Nagar, Gulabi Bagh, New Delhi-110007, INDIA
Correspondence Address: Tulip 3P Media Pvt. Ltd. 207-B, Second Floor, NDM-2, Plot No. D-1, 2 & 3, Netaji Subhash Place, Pitam Pura, New Delhi-110034, INDIA, Tel.:+91 11 45678 421 / 22 / 23 Mob.: +91 99999 350 11 / 22 / 44, E-mail : info@papermart.in / info@tulip3pmedia.in International Sales : RNP Nicolas Pelletier 16, rue Bannier 45000 Orleans, France Tel.: +33 682 25 12 06, Fax: +33 238 422910 Chinese Representative: China Pulp & Paper Industry Publishing House No. 101, Gongyenan Road, Jinan Shandong, China Tel.: +86 531 88522949 Owned, Published & Printed By : Parveen Kumar Jain, Published at 218, Sanjay Nagar, Gulabi Bagh, Delhi-110007, INDIA. Printed at: Pankaj Paper Mart, 218, Sanjay Nagar, Gulabi Bagh, Delhi-110007, INDIA. All disputes regarding this magazine will be settled in Delhi (India) Jurisdiction Only. The views expressed in the columns of Paper Mart are not necessarily those of the editor or the publisher & they accept no responsibility for them. CAUTION: No part of this magazine including advertisements designs, prepared by us or through us should be copied, reproduced or transmitted by any one without prior written permission of the publisher.
16-18, March 2022
Tissue World Miami
Miami, USA www.tissueworld.com/miami
84 | www.papermart.in / August-September, 2020
Paper Mart Partner magazine :
I
www.papermart.in http://emagazine.papermart.in